Skoda Rapid Body Work Eng

Service
Workshop Manual
Rapid NH 2014 ➤
Rapid Spaceback 2014 ➤
Body Work
Edition 10.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
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
68 - Interior equipment
69 - Passenger protection
70 - Trim, insulation
72 - Seat frames
74 - Seat - padding, covers
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.
Rapid NH 2014 ➤ , Rapid Spaceback 2014 ➤
Body Work - Edition 10.2018
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Front body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Lock carrier with components parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Removing and installing lock carrier with component parts . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Removing and installing the wing support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Bulkhead plenum chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8 Plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.9 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.10 V-ribbed belt protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.11 Underfloor trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.12 Tunnel bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1 Front flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 Removing and installing the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Removing and installing the hinge for the front flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Removing and installing the support bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Lock and unlock components of front flap - Summary of components . . . . . . . . . . . . . . . . 25
1.6 Removing and installing front flap lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Separating the Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.8 Removing and installing the locking clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.9 Removing and installing the operating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.10 Adjusting the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Removing and installing tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Removing and installing the locking mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Adjusting tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.5 Removing and installing the tailgate lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6 Removing and installing pressurized gas strut of tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7 Tailgate seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Fuel tank lid unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Fuel-tank lid unit - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2 Removing and installing fuel tank lid unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 Fuel-tank lid unit (Spacebook)- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Removing and installing fuel tank lid unit (Spacebook) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.1 Assembly overview - door hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Removing and installing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.3 Door adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Front door - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2 Removing and installing the door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Door handle and door lock - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4 Removing and installing cap for lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
2.6 Removing and installing cap (without lock cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.7 Removing and installing the door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.8 Removing and installing the door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.9 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.10 Front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.11 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.12 Removing and installing window lifter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.13 Remove and install window lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.14 Removing and installing the window run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.15 Removing and installing the inner window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.16 Removing and installing the outer window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.17 Removing and installing the inside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.18 Removing and installing the outside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1 Adjustment of radio control keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Summary of components – battery for the (foldable) radio control key . . . . . . . . . . . . . . . . 85
3.3 Removing and installing the battery for the foldable key with radio remote control . . . . . . 86
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Assembly overview - door hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Removing and installing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Door adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Door internal parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.2 Removing and installing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.3 Removing and installing the door retaining strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Removing and installing the locking clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.5 Door handle and door lock - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.6 Removing and installing the cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.7 Removing and installing the door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.8 Removing and installing the door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.9 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.10 Rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.11 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.12 Removing and installing window lifter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.13 Removing and installing the manual drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.14 Removing and installing window crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.15 Remove and install window lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.16 Removing and installing the window run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.17 Removing and installing the rear fixed door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.18 Removing and installing the rear fixed door window (Spaceback) . . . . . . . . . . . . . . . . . . . . 120
2.19 Removing and installing the inner window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.20 Removing and installing the outer window channel strip . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.21 Removing and installing the inside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.22 Removing and installing the outside door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1 Panoramic roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.1 Summary of components of panoramic roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.2 Removing and installing panoramic roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Removing and installing roof roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
ii Contents
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.2 Front bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.2 Rear bumper bracket and runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3 Rear bumper (Spacebook) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4 Cutting out the openings for the parking aid sensors (drill) . . . . . . . . . . . . . . . . . . . . . . . . 140
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1 Glued windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.3 Windscreen - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.4 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.5 Rear window - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.6 Removing and installing the rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.7 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.8 Extended rear window (Spacebook)- Summary of components . . . . . . . . . . . . . . . . . . . . 149
1.9 Removing and installing extended rear window (Spacebook) . . . . . . . . . . . . . . . . . . . . . . 150
1.10 Removing and installing side window (Spacebook) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.11 Removing and installing side window (Spacebook) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.12 Preparing the new window for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.13 Prepare body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.14 Installation instructions for all panes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.15 Minimum hardening time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.16 Window repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.17 Cleaning necessary due to soiling through glue sealing material . . . . . . . . . . . . . . . . . . . . 157
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

1 Wheelhouse liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Front wheelhouse liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.2 Rear wheelhouse liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2 Exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 Strips and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 Summary of components - trim strips and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Removing and installing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3 Removing and installing door sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.4 B-pillar trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.5 Cover strip of wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4 Rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.1 Rear spoiler - Rapid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.2 Rear spoiler - Spaceback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5 Letterings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.1 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.2 Removing and installing the emblem on the tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.3 Dimensions of letterings on the tailgate - Spaceback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.4 Dimensions of letterings on the tailgate - Rapid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.5 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
68 - Interior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1 Interior rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Contents iii
1.2 Removing and installing the interior rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1.3 Glueing the retaining plate for the interior rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . 199
2 Covers, storage areas and trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.2 Centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.3 Summary of components – armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.4 Removing and installing the sustainer (vehicles with armrest) . . . . . . . . . . . . . . . . . . . . . . 205
2.5 Removing and installing the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.6 Removing and installing the sun visor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3 Recessed handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.1 Removing and installing the recessed handles of the roof . . . . . . . . . . . . . . . . . . . . . . . . . . 210
69 - Passenger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

1 Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.1 Removing and installing the front seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.2 Removing and installing the front seat belt height adjuster . . . . . . . . . . . . . . . . . . . . . . . . 214
1.3 Removing and installing the front seat belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
1.4 Removing and installing the front seat belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.5 Removing and installing the outer rear seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.6 Removing and installing the rear middle seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.7 Removing and installing the rear seat belt buckle with lap belt . . . . . . . . . . . . . . . . . . . . . . 218
1.8 Removing and installing the rear double belt buckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2 Inspect seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.1 Test sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.2 Special instructions for the belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.3 Storage, transport and disposal of airbag, belt tensioner and battery separation units
(pyrotechnical components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.2 Airbag system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.3 Observe the general safety instructions for working on airbag, belt tensioner and battery
separation units (pyrotechnical components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.4 Special instructions for driver and front passenger airbag . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.5 Storage, transport and disposal of airbag, belt tensioner and battery separation units
(pyrotechnical components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.6 Replacing parts of the airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.7 Removing and installing the airbag control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.8 After replacement, configure the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.9 Installing and removing sensor for side impact on the B-pillar . . . . . . . . . . . . . . . . . . . . . . 230
3.10 Installing and removing sensor for side impact on the C-pillar . . . . . . . . . . . . . . . . . . . . . . 230
3.11 Removing and installing front passenger airbag key switch . . . . . . . . . . . . . . . . . . . . . . . . 231
3.12 Summary of components of steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.13 Removing and installing driver airbag unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.14 Removing and installing restoring ring with slip ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.15 Removing and installing airbag unit on the passenger side . . . . . . . . . . . . . . . . . . . . . . . . 235
3.16 Removing and installing side airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.17 Head airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
70 - Trim, insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

1 Dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.1 Removing and installing the dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.2 Removing and installing the glove compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.3 Removing and installing the steering column trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.4 Removing and installing the decorative trim of the dash panel . . . . . . . . . . . . . . . . . . . . . . 251
1.5 Removing and installing the cross member for the dash panel . . . . . . . . . . . . . . . . . . . . . . 252
1.6 Removing and installing impact absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
iv Contents
2 Door and side trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

2.1 Removing and installing the front door trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.2 Removing and installing the rear door trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3 Trim panels of pillars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.1 Removing and installing top trim panel of pillar A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.2 Removing and installing bottom trim panel of pillar A on the driver's side . . . . . . . . . . . . . . 264
3.3 Removing and installing bottom trim panel of pillar A on the front passenger side . . . . . . 265
3.4 Removing and installing top B-pillar trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.5 Removing and installing bottom B-pillar trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.6 Removing and installing trim panel of pillar C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.7 Removing and installing C and D pillar trim panels (Spaceback) . . . . . . . . . . . . . . . . . . . . 270
3.8 Door sill panel and wheel house trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4 Tailgate trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.1 Removing and installing tailgate trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.2 Removing and installing the tailgate trim panel (Spaceback) . . . . . . . . . . . . . . . . . . . . . . . . 275
5 Luggage compartment trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.1 Removing and installing the tailgate/luggage compartment cover . . . . . . . . . . . . . . . . . . . . 277
5.2 Removing and installing top part of side luggage compartment trim panel . . . . . . . . . . . . 278
5.3 Removing and installing side luggage compartment trim panel . . . . . . . . . . . . . . . . . . . . . . 279
6 Removing and installing side luggage compartment trim panel . . . . . . . . . . . . . . . . . . . . . . 281
7 Moulded headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.1 Removing and installing moulded headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.2 Removing and installing the dampings and roof reinforcements . . . . . . . . . . . . . . . . . . . . 284
72 - Seat frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

1 Front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.1 Removing and installing front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.2 Removing and installing the seat upholstery on the rail side (seat without height
adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1.3 Removing and installing the seat upholstery on the rail side (seat with height adjustment)
........................................................................ 289
1.4 Removing and installing the operating lever of the seat height adjustment . . . . . . . . . . . . 291
1.5 Removing and installing the seat trim panel on the tunnel side . . . . . . . . . . . . . . . . . . . . . . 291
1.6 Removing and installing the grip for the seat height adjuster . . . . . . . . . . . . . . . . . . . . . . . . 292
1.7 Removing the headrest guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2 Rear seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2.1 Removing and installing the rear seat bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3 Removing and installing backrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
74 - Seat - padding, covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

1 Covers and upholstery of the front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
1.2 Removing and installing the cover and the upholstery of the front seat cushions . . . . . . . . 299
1.3 Removing and installing the cover and the upholstery of the front seat backrest . . . . . . . . 301
2 Rear covers and seat upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.2 Removing and installing cover and seat upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2.3 Removing and installing entire cover and backrest upholstery . . . . . . . . . . . . . . . . . . . . . . 308
Contents v
vi Contents
50 – Body - front
1 Front body
(SRL001304; Edition 10.2018)
1.1 Tools
Special tools and workshop equipment required
♦ Guide bars - T30092 (3411)-
1.2 Lock carrier with components parts

Summary of components
Note
Depending on the model version, slight differences in the mounting parts are possible.
1. Front body 1
1 - Lock carrier with compo‐

nents parts
❑ Service position
⇒ “1.3 Service position ”,
page 2 .
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling lock carrier with
component parts”,
page 4 .
2 - Hose clamp
3 - Air guide duct
4 - Screw
❑ Tightening torque - 2
Nm.
5 - Screw
Nm.
6 - Screw
Nm.
7 - Lock carrier - top compo‐
nent parts
8 - Air deflector
9 - Screw
Nm.
10 - Screw
Nm.
11 - Bumper bracket
12 - Air deflector
1.3 Service position

Carry out the service position
2 Rep. gr.50 - Body - front

– Removing front bumper ⇒ “1.1.2 Removing”, page 132 .

– Pull off the control cable from the lock carrier
⇒ “1.7 Separating the Bowden cable”, page 28 .
– Remove the screws -3- at the left and right frame side rails.
– Install the guide bars - T30092 (3411)- on the left and right
frame side rails.
– Remove top screws - 2 -.
– The lock carrier -1- can be pulled on the guide bars - T30092
(3411)- by approx. 10 cm forwards -arrows-.
1. Front body 3
1.3.1 Reinstallation
– Install screws -2- and -3-.

– Take the mean of the lock carrier with component parts -1- at
the frame side rails and between the wings ⇒ Body Repairs;
Rep. gr. 00 ; technical data; body gaps; front body .
– Tightening torque of screws (Pos. 2) is 20 Nm.
– Tightening torque of screws (Pos. 3) is 30 Nm.
– Further installation occurs in reverse order.
Note
Hoses and lines must not be pinched.
1.4 Removing and installing lock carrier with

component parts
Removing

– Bring to service position ⇒ “1.3 Service position ”, page 2 .

– Separate electrical plug connections.
– Drain the coolant and separate the coolant line ⇒ Engine
cooling; Rep. gr. 19 .
– Separate the lines for the condenser ⇒ Heating and air con‐
ditioning system; Rep. gr. 87 .
– Remove the guide bars - T30092 (3411)- at the left and right
frame side rails - 2 - with the help of a second mechanic and
remove the lock carrier with component parts - 1 -.
WARNING
If the cables of the air-conditioning system and/or the coolant

are separated, the drive unit must no longer be started.
Note
♦ The condenser and hydraulic oil cooler must not be tied up to the cables.
♦ The condenser and hydraulic lines must not be kinked.
1. Front body 5
Installing
– Position the lock carrier - 1 - on the frame side rails - 2 -.

– Install the left and right guide bars - T30092 (3411)- .
– Resetting service position ⇒ “1.3.1 Reinstallation”, page 4 .
• Make sure that the plug connections and the hose connections
are correctly mounted during assembly.
– Take the mean of the lock carrier at the frame side rails and
between the wings ⇒ Body Repairs; Rep. gr. 00 ; technical
data; body gaps; front body .

1.5 Front wing
1.5.1 Summary of components
1 - Wing
❑ Removing
⇒ “1.5.2 Removing front
wing”, page 8 .
❑ Installing
⇒ “1.5.3 Installing the
front wing”, page 10 .
2 - Screw
Nm.
3 - Screw
Nm.
4 - Wing support
stalling the wing sup‐
port”, page 11 .
5 - Interior trim
⇒ “1.5.2 Removing front
wing”, page 8 .
6 - Foam part
❑ Inserted between the
wing and the front top
frame side rail.
7 - Damping of interior trim
1. Front body 7
1.5.2 Removing front wing
– Remove front wheelhouse liner

⇒ “1.1 Front wheelhouse liner”, page 158 .
– Remove side turn signal ⇒ Electrical System; Rep. gr. 94 .
– On vehicles fitted with a damping, first of all remove the damp‐
ing.
– Loosen catch hook -3- and clip -2-.
– Slightly pull the interior trim -1- in the lower area forwards
-arrow b- and then guide it out towards the bottom -arrow a-.

Carry out the following tasks

– Removing front bumper ⇒ “1.1.2 Removing”, page 132 .
– Pull out the foam part between the wing and the frame side
rail.
– Pull the damping of the interior trim out of the wheelhouse.
– Unscrew screw -2-.
– Unscrew screws -3-.
– For this step the bumper holder -4- must not be removed.
– The rear screw -2- can be reached when the front flap is
closed. Cover the front flap with adhesive tape in order to pro‐
tect it from damage.
– Carefully remove the wing - 1 -.
1. Front body 9
1.5.3 Installing the front wing

– The installation of the wing - 1 - occurs in the reverse order.
– Tightening torque of screw -2- (4 Nm).
– Tightening torque of screws -3- (8 Nm).
– Observe the parallelism and the correct gap sizes ⇒ Body Re‐
pairs; Rep. gr. 00 ; technical data; body gaps; front body .
The wing support must be loosened when the fitting is carried out
⇒ “1.6 Removing and installing the wing support”, page 11 .
Note
Install the wing -1- free of stress.

1.6 Removing and installing the wing support
Removing
– Remove front bumper cover ⇒ “1.1.2 Removing”, page 132 .
– Release screws - 3 - and remove wing support - 2 -.
Installing
– Install wing support - 2 -.
– Adapt wing support with the wing -1- to the front flap and
bumper ⇒ Body Repairs; Rep. gr. 00 ; Technical data; body
gaps; front body .
1. Front body 11
1.7 Bulkhead plenum chamber
1 - Bulkhead plenum chamber

Removing
– Remove the plenum

chamber cover
⇒ “1.8.2 Removing”,
page 14 .
– Remove engine air duct

(depending on engine).
– Remove engine control

unit and engine control
module holder.
– Remove noise insula‐

tion.
– Remove the bulkhead

plenum chamber -1- up‐
wards and out of the ple‐
num chamber -4-.
Installing
– The installation occurs

in reverse order.
2 - Screw
Nm.
3 - Plenum chamber
4 - Seal
Note
Ensure that the seal is correctly

seated when installing the bulkhead
plenum chamber.
5 - Damping
❑ Attached to the bulkhead plenum chamber with clamping plates.
6 - Circlip
❑ For attaching the damping on the bulkhead plenum chamber.

1.8 Plenum chamber cover
1 - Additional cover
❑ Fitted on the wing web
plate.
2 - Plenum chamber cover
❑ Removing
page 14 .
❑ Installing
⇒ “1.8.3 Installing”,
page 15 .
3 - Additional cover
❑ Fitted on the wing web
plate.
4 - Moulded foam part
5 - Seal
6 - Moulded foam part
1. Front body 13
1.8.2 Removing
– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .

– Detach the seal -2- along the entire length of the plenum
chamber cover -1-.
Caution
The plenum chamber cover must not be levered off with a lever
tool (screwdriver, wedge). The washer is damaged and can
subsequently tear.
– Lift up the plenum chamber cover -1- on the edge of the wind‐
screen by hand.
– Pull the plenum chamber cover -1- starting at the edge of the
windscreen -6- towards the top and out of the fitting section
-5-.
– Remove plenum chamber cover -1- from vehicle.

1.8.3 Installing
Caution
Breaking open the plenum chamber cover -1- in the fitting sec‐
tion -5- of the windscreen -6- can lead to cracks in the wind‐
screen.
Note
♦ An inlay is installed in the fitting section on new windscreens. This inlay must be removed before installing
the plenum chamber cover.
♦ The plenum chamber cover must be slightly pressed into the fitting section by hand, but on no account knock
or press in using a tool.

– Wet the fitting section -5- with soapy water so that the plenum
chamber covers -1- can be pressed in more easily.
1. Front body 15
– Place the plenum chamber covers -1- onto the fitting section
-5- and clip it, starting from the centre, into the fitting section
-5- with slight pressure.
– Fit the seal - 2 - onto the plenum chamber cover - 1 -.
– Installing windscreen wipers ⇒ Electrical System; Rep. gr.
92 .
1.9 Noise insulation
Note
Depending on the model version, slight differences must be taken into consideration when removing and in‐
stalling.
1 - Noise insulation
Removing
– Remove the screws -2-

and push out the noise
insulation towards the
rear.
2 - Screw
Nm.
3 - Shock absorber cover

1.10 V-ribbed belt protection
1 - V-ribbed belt protection

Removing
Installing

in reverse order.
2 - Screw
Nm.
3 - Snap nut
1. Front body 17
1.11 Underfloor trim panel
1 - Floor covering
Removing
– Unscrew nuts - 2 -.
Installing

in reverse order.
2 - Nut
Nm.
3 - Threaded bores
❑ Welded to the floor pan‐
el.

1.12 Tunnel bridge
1 - Tunnel bridge
Removing
– Remove underbody
panels
⇒ “1.11 Underfloor trim
panel”, page 18 .
Installing
in reverse order.
2 - Nut
Nm.
3 - Threaded bores
❑ Welded to the floor pan‐
el.
1. Front body 19
55 – Bonnet, rear lid

1 Front flap
1.1 Summary of components
1 - Front flap
page 21 .
❑ Setting
⇒ “1.10 Adjusting the
bonnet”, page 32 .
2 - Plug
3 - Adjusting buffer
4 - Locking clamp
5 - Damping
Removing
– Unclip all the clips for

the damping in se‐
quence.
– Remove the damping

from the bonnet.
Installing

in reverse order.
6 - Bump stop
7 - Adjusting buffer
8 - Plug
9 - Hinge
stalling the hinge for the
front flap”, page 23 .
❑ Setting
⇒ “1.10 Adjusting the bonnet”, page 32 .
10 - Spray nozzles
❑ Removing and installing ⇒ Electrical System; Rep. gr. 92 .
11 - Support bar
❑ Removing and installing ⇒ “1.4 Removing and installing the support bar”, page 24 .
12 - Flap lock bonnet
❑ Removing and installing ⇒ “1.6 Removing and installing front flap lock ”, page 25 .
13 - Screw
❑ Tightening torque - 20 Nm.
14 - Nut
❑ Tightening torque - 20 Nm. Volkswagen Technical Site: http://vwts.ru http://vwts.info
20 Rep. gr.55 - Bonnet, rear lid

15 - Retaining clip
1.2 Removing and installing the bonnet
1.2.1 Removing
– Remove spray nozzles -5- ⇒ Electrical System; Rep. gr. 92 .

– Unclip the cable -4- from the front flap -1-.
– Pull the cable -4- out of the opening of the front flap -1-.
– Slacken the nuts -3- on the left and right at the hinge -2- (do
not unscrew).
Carry out further removal only with the assistance of a second
mechanic.
– Remove support bar -6- from the front flap.
– Only now unscrew the nuts -3- and lift the front flap -1- out of
the hinges -2-.
1. Front flap 21
1.2.2 Installing
Installing
– The installation occurs in reverse order.
– Adjust front flap -1-
⇒ “1.10 Adjusting the bonnet”, page 32 .

1.3 Removing and installing the hinge for

the front flap
1.3.1 Removing
– Remove front flap -3- ⇒ “1.2.1 Removing”, page 21 .

– Remove screws -2- (20 Nm).
– Remove hinge - 1 -.
1.3.2 Installing
1. Front flap 23
1.4 Removing and installing the support bar
Removing
– Support the bonnet.
– Swivel the support bar - 1 - towards the front and pull the sup‐
port bar out of the rubber grommet - 2 -.
Installing
– Push the support bar -1- into the rubber grommet (Pos.2)
-arrow a-.
– Swivel the support bar towards the lock carrier -arrow b-.
– Check the bracket -3- for damage, replace it if necessary.

1.5 Lock and unlock components of front flap - Summary of components
1 - Locking clamp
❑ Removing
stalling the locking
clamp”, page 29 .
❑ Setting
⇒ “1.10.2 Adjusting the
locking clamp”,
page 34 .
2 - Release handle
⇒ “1.9.2 Removing and
installing”, page 31 .
3 - Bowden cable
❑ From the Bowden cable
coupling to the operat‐
ing lever
stalling the operating
lever”, page 30 .
4 - Retaining clip
5 - Bowden cable
6 - Bowden wire coupling
❑ The Bowden cable cou‐
pling is located above
the headlight on the
driver's side.
❑ Separate
⇒ “1.7 Separating the
Bowden cable”,
page 28 .
7 - Bowden cable
❑ From the front flap lock
to the Bowden cable
coupling.
❑ Clipped into the Bowden cable coupling.
8 - Flap lock bonnet
❑ Remove and install front flap lock ⇒ “1.6 Removing and installing front flap lock ”, page 25 .
❑ Setting ⇒ “1.10.1 Adjusting the flap lock”, page 33 .
1.6 Removing and installing front flap lock
Note
Depending on the model version, slight differences must be taken

into consideration when removing and installing the front flap lock.
1. Front flap 25
1.6.1 Removing
Note
The Bowden cable -2- is not separated from the front flap lock.
– Open front flap.

– Separate the Bowden cable -2- in the Bowden cable coupling
– Depending on the additional equipment, disconnect the plug
connection for the contact switch of the engine hood.
– Release the screws - 4 - (12 Nm) and remove the flap lock
- 1 - in - direction of arrow a - from the lock carrier.
Note
Depending on the additional equipment, remove and install the contact switch for the engine hood at the flap
lock ⇒ Electrical System; Rep. gr. 96 .

1.6.2 Installing
– Clip the end part - 3 - of the Bowden cable - 2 - into the flap
lock (if it was removed) - arrow a -.
– Push the flap lock -1- into the lock carrier -arrow b-.
– Depending on the additional equipment, connect the plug con‐
nection for the contact switch of the engine hood.
– Install the Bowden cable -2- in the Bowden cable coupling
– Adjust flap lock ⇒ “1.10.1 Adjusting the flap lock”, page 33 .
• Before closing the front flap, carry out a functional test of the
operating lever and the Bowden cable.
1. Front flap 27
1.7 Separating the Bowden cable
Removing
– Open front flap.
– Unclip the Bowden cable coupling - 2 -, located above the
headlight on the driver's side, out of the lock carrier
-arrow a-.
– Take the Bowden cables -1- and -3- out of the Bowden cable
coupling -2- in -arrows a-.
– Swivel the Bowden cable -1- about 90° in
-direction of arrow b- and take the Bowden cable
-in direction of arrow c- out of the support of the Bowden cable.
Installing

Note
♦ When installing the Bowden cable - 3 -, ensure that the grommet - 5 - is correctly secured.
♦ When attaching the Bowden cable - 3 -, pay attention to the mandatory clipping - 4 -.
• Before closing the front flap, carry out a functional test of the
operating lever and the Bowden cable.
1.8 Removing and installing the locking clamp
Removing
– Remove the locking clamp - 1 - from the front flap - 2 -.
Installing
– Adjust the locking clamp to the flap lock
⇒ “1.10.2 Adjusting the locking clamp”, page 34 .
1. Front flap 29
1.9 Removing and installing the operating

lever
1 - Bearing bracket
2 - Bowden cable
Installing
– Insert the ball of the

Bowden cable into the
bracket -arrow a- and
secure the Bowden ca‐
ble in the bearing brack‐
et -arrow b-.
3 - Expanding nut
4 - Screw
Nm.
5 - Release handle
installing”, page 31 .

1.9.2 Removing and installing
Removing
– Tighten the operating lever -1- and unlock the bonnet.
– Fit a small screwdriver into the gap between the operating
lever - 1 - and the retaining clip - 2 -.
– Lever the retaining clip -2- out of the operating lever (Pos. 1)
-arrow- and detach the operating lever from the bearing brack‐
et -3-.
When carrying out further work on the bearing bracket - 3 -, re‐
move the bottom A pillar trim panel - 4 -.
Installing
• The bottom A pillar trim panel -4- is installed.
– Push the retaining clip -2- into the operating lever.
– Press the operating lever - 1 - onto the bearing bracket - 3 -.
1. Front flap 31
1.10 Adjusting the bonnet
Note
♦ The vehicle must be positioned on the flat ground in order to adjust the bonnet.
♦ The adjusting buffers -2- on the left and right are not used for the adjustment. They have the function to
stabilise or dampen the bonnet.
♦ The bonnet is correctly adjusted if in the closed state it has an overall even gap size, is not positioned too
far outwards or inwards and the contours are aligned.
♦ The bonnet must latch in the flap lock without using increased force.
♦ The nuts are not unscrewed, only slackened.
– Remove locking clamp -1-

⇒ “1.8 Removing and installing the locking clamp”, page 29 .
– The mean of the front flap can be taken between the wings by
slackening the nuts -6- on the left and right hinges -7-.
– Ensure parallelism of gap dimensions ⇒ Body Repairs; Rep.
gr. 00 ; Technical data; body gaps; front body .

Adjusting the adjusting buffer
Note
♦ Install the adjusting buffer - 2 and 3 - on the left and right up to the stop.
♦ Turn the adjusting buffers by 90° if required, in order to pretension the flap.
– After the front flap has been adjusted, the locking clamp - 1 -
can once again be installed and adjusted
– The front flap can be adjusted in the front area to the height of
the wings with the flap lock -5-
⇒ “1.10.1 Adjusting the flap lock”, page 33 .
– After the flap has been adjusted, the locking clamp has been
installed and all the connections have been tightened, the ad‐
justing buffers can be turned if required.
– After carrying out adjustment work, perform corrosion protec‐
tion measures on the hinges -6- and the screws -7- .
1.10.1 Adjusting the flap lock
1. Front flap 33
– If the screws -2- are loosened, the front flap lock -1- can be
adjusted to the front flap laterally -arrow a- and in height
-arrow b- ⇒ Body Repairs; Rep. gr. 00 ; body gaps; front body .
1.10.2 Adjusting the locking clamp
– Release screws - 3 -.
– The locking clamp -1- can now be adjusted in the oversized
holes.

2 Tailgate
1 - Screw
Nm.
2 - Wedge buffer
3 - Tailgate trim panel
⇒ “4 Tailgate trim pan‐
el”, page 274 .
4 - Tailgate
stalling tailgate”,
page 36 .
❑ Setting
⇒ “2.4 Adjusting tail‐
gate”, page 37 .
5 - Rubber buffer
❑ Setting
⇒ “2.4.2 Adjusting the
rubber buffer”,
page 39 .
6 - Ball pin
– Tightening torque - 20
Nm.
7 - Pressurized gas strut

– Removing and installing
stalling pressurized gas
strut of tailgate”,
page 40 .
2. Tailgate 35
2.2 Removing and installing tailgate
2.2.1 Removing
– Remove the tailgate trim panel

⇒ “4 Tailgate trim panel”, page 274 .
– Disconnect the plug connections of the existing electrical com‐
ponents.
– Thread the electrical cables out of the tailgate.
– Slacken the screws - 3 - (10 Nm) on the left and right hinges
but do not yet unscrew.
Carry out further removal only with the assistance of a second
mechanic.
– Only now unscrew the screws - 3 - and remove the tailgate.
– Only if the complete hinge for the tailgate must be removed,
release the nuts - 2 - (20 Nm). In this case the moulded head‐
liner must be unhooked ⇒ “7 Moulded headliner”, page 282 .

Installing
Note
Adjust the tailgate after installing ⇒ “2.4 Adjusting tailgate”, page 37 .
2.3 Removing and installing the locking

mechanism
2.3.1 Removing
– Unscrew screw -2- and remove the closing wedge -1- from the
luggage compartment wall.
Installing
– Set the locking mechanism
⇒ “2.4.1 Setting the locking mechanism”, page 39 .
2.4 Adjusting tailgate
Note
♦ The vehicle must be standing on its wheels in order to adjust the tailgate.
♦ The flap lock is directly screwed onto the tailgate. It has no elongated holes and therefore it cannot be
adjusted.
♦ The adjusting buffers on the left and right are not used for the adjustment. They have the function to stabilise
or dampen the bonnet.
♦ The bonnet is correctly adjusted if in the closed state it has an overall even gap size, is not positioned too
far outwards or inwards and the contours are aligned.
♦ The tailgate must latch in the flap lock without using increased force.
2. Tailgate 37
Use a setting gauge for setting or checking the gap sizes ⇒ Body
Repairs; Rep. gr. 00 ; Body gaps; rear body .
– The tailgate can be adjusted in the oversized bores of the
hinges horizontally and vertically by slackening the screws
- 3 -.
Tightening torque of screws -3- (10 Nm).
– After carrying out adjustment work, perform corrosion protec‐
tion measures at the hinges and screws.
– Adjust the tailgate on the closing wedge
⇒ “2.4.1 Setting the locking mechanism”, page 39 .
– Adjust the rubber buffer on the left and right
⇒ “2.4.2 Adjusting the rubber buffer”, page 39 .

2.4.1 Setting the locking mechanism
Note
♦ The closing wedge -2- can be moved in the oversized bores

-arrows a- and -arrows b- by loosening the screws - 1 -.
♦ Set the locking mechanism - 2 - in such a way that the recess
of the tailgate lock with the catch engages centrally in the
locking mechanism - 2 -.
– Release screws - 1 -.
– Push the locking mechanism -2- out into the upper position
and tighten the screws -1-.
– Close the tailgate and check the setting.
2.4.2 Adjusting the rubber buffer

– Adjust the rubber buffer in such a way that no excessive forces
must be used when closing the tailgate -1- and that it engages
in the lock.
– Remove rubber buffers -2- by approximately 2 mm out of the
tailgate -1-.
– The tailgate -1- must latch in the flap lock without using in‐
creased force.
2.5 Removing and installing the tailgate lock
Note
If the tailgate does not open, the emergency release can be

opened mechanically from the luggage compartment via the lock
cylinder ⇒ Owner's Manual .
2. Tailgate 39
Removing
– Remove lock cover - 3 -.
– Disconnect the plug connection from the tailgate lock control
- 1 -.
– Release the nuts -2- (21 Nm) and remove the flap lock -1- from
the tailgate.
Installing
2.6 Removing and installing pressurized

gas strut of tailgate
Removing
– Open tailgate, support and lock it into position.
– Use a screwdriver to raise the locking element - 2 - and pull
the pressurized gas strut - 1 - off the ball stud - 3 -.
Note
If the pressurized gas strut is to be re-used, do not remove the

locking device fully from the ball socket, otherwise it will be dam‐
aged.
– 1 - Pressurized gas strut

– 2 - Locking device
– 3 - Ball stud
Installing

2.7 Tailgate seal
2.7.1 Installation instructions

♦ If the seal is re-installed, leak-tightness and tight fit can no
longer be guaranteed.
♦ For this reason, each seal which was completely removed
must be replaced with a so-called “hammer finish seal”.
♦ If the seals were detached partially, press together the sides
of the seal before installing.
2.7.2 Removing and installing tailgate seal
Removing
– Pay attention to installation instructions
⇒ “2.7.1 Installation instructions”, page 41 .
– Detach the seal for the tailgate -1- from the body flange.
Installing
– Press the seal -1- evenly onto the body flange.
2. Tailgate 41
3 Fuel tank lid unit
3.1 Fuel-tank lid unit - Summary of components
1 - Locking mechanism
2 - Fuel tank lid unit
stalling fuel tank lid unit”,
page 42 .
3 - Water drain hose
❑ Laid between the wheel‐
house and the wheel‐
house liner.
3.2 Removing and installing fuel tank lid unit

3.2.1 Removing
– First pierce the unit in the upper area with a thin screwdriver
- 4 - or a nail - 1 - - 2 - in the - direction of arrow a - .
– Lightly ress the screwdriver in the -direction of arrow b - the
catches - 5 - will be unlocked as a result.
– After unlocking the upper latches, slightly swivel the unit out
of the side panel. The lower catches should then extend up‐
wards. If the lower area can not be removed, proceed as in the
upper area.
– Remove the rubber grommet from the fuel filler neck.
– Remove the fuel tank lid unit from the side section.
3.2.2 Installing

Note
If the latches for the fuel tank lid unit are damaged, use a new
part.
3.3 Fuel-tank lid unit (Spacebook)- Summary of components
1 - Fuel tank lid

2 - Fuel tank lid unit
Removing and installing
⇒ “4 Removing and installing
fuel tank lid unit (Spacebook)”,
page 44 .
3 - Water drain hose

4 - Locking mechanism
5 - Fuel filler neck
6 - Side section
3. Fuel tank lid unit 43

4 Removing and installing fuel tank lid unit (Spacebook)
Removing
– Unlock the catches - arrows -, which are clipped onto the side
panel- 2 -, in the same way as in the Rapid model
⇒ “3.2 Removing and installing fuel tank lid unit”, page 42 .
– Remove fuel tank lid unit - 1 - outwards.
Installing
– Perform the installation by pressing in the fuel tank lid unit in
the lateral part. Latch the fuel tank lid unit for the correct po‐
sition until it audibly clicks into place.
Note
If the latches for the fuel tank lid unit are damaged, use a new part.

57 – Front doors, door components, central locking

1 Front door
1.1 Assembly overview - door hanger
Note
Always replace the screws for the door hinges after the removal.
1 - Door
stalling the door”,
page 47 .
❑ Setting
⇒ “1.3 Door adjust‐
ment”, page 49 .
2 - Multi-point socket head bolt
❑ 32 Nm.
❑ Always replace the
screws after the remov‐
al.
3 - Door hinge
❑ The top part is connec‐
ted to the bottom part of
the hinge by the screw
- 4 -.
4 - Screw
❑ This screw must be un‐
screwed in order to re‐
move the door from the
hinge.
❑ 23 Nm.
❑ Installed from the inside
of the vehicle.
❑ Remove bottom A-pillar
trim panel.
❑ 32 Nm.
al.
6 - Door hinge
❑ The bottom part is connected to the top part of the hinge by the screw -4-.
❑ 32 Nm.
❑ Always replace the screws after the removal.
8 - Screw
❑ 32 Nm.
❑ 30 Nm - only for the assembly plant in Russia.
Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Front door 45

❑ This screw must be unscrewed in order to remove the door.
9 - Door retaining strap
10 - Screw
❑ 9 Nm.
❑ Installed from the inside of the vehicle.
❑ Remove and install the dash panel for loosening or tightening the screw on the driver's side
⇒ “1.1 Removing and installing the dash panel”, page 244 .
❑ Remove and install the dash panel for loosening or tightening the screw on the front passenger side
❑ 32 Nm.
12 - Door hinge
❑ 32 Nm.
❑ 32 Nm.
15 - Door hinge
❑ The top part is connected to the bottom part of the hinge by the screw - 12 -.
16 - Screw
❑ 23 Nm.
❑ This screw must be screwed down in order to remove the door from the hinge bolt.
46 Rep. gr.57 - Front doors, door components, central locking

1.2 Removing and installing the door
1.2.1 Removing
– Release the bellows -2- by pressing on the catch -arrow a- and

detach it from the A pillar.
– Swivel the release lever -3- downwards -arrow b- and discon‐
nect the el. plug connection -4- from the connector station.
– Slacken the screws -7- at the hinges -arrows d-.
– Remove the screws -5- for the door retaining strap -6-.
– Pull the door -1- upwards -arrow e- and out of the hinges -8-.
1. Front door 47
1.2.2 Installing
Installing
– Tightening torques of screws
⇒ “1.1 Assembly overview - door hanger ”, page 45 .
– Observe the gap sizes of the front door ⇒ Body Repairs; Rep.
gr. 00 ; technical data; body gaps; front body .

1.3 Door adjustment
Note
♦ The vehicle must be standing on its wheels in order to adjust the door.
♦ The door is correctly adjusted if in the closed state it has an overall even gap size, is not positioned too far
outwards or inwards and the contours are aligned.
♦ For checking the gap sizes: ⇒ Body Repairs; Rep. gr. 00 ; Technical data; body gaps; front body .
♦ After carrying out adjustment work, perform corrosion protection measures at the screws and hinges.
Setting the gap sizes

In order to correctly set the gap sizes, the screws
-2, 5, 7, and 8- must be slackened at the A pillar.
– The bottom A pillar trim panel must be removed for slackening
the screw -5-
⇒ “3.2 Removing and installing bottom trim panel of pillar A on
the driver's side”, page 264 .
1. Front door 49
– The dash panel must be removed on the driver's side for

slackening the screw - 7 -
– The glove compartment must be removed on the front pas‐
senger side for slackening the screw - 7 -
⇒ “1.2 Removing and installing the glove compartment”, page
249 .
The screws -3 and 9- must be released for correctly setting the
flushness.
Note
Other measures, such as aligning the doors towards the top are ineffective. The door will drop again at the
following overpressures.
Adjusting the locking clamp


Note
♦ The arc outside the threaded plate must be firmly welded to the pillar. The lands to the threaded plate are
malleable.
♦ To adjust the locking clamp -2- once the screws -3- are loosened, increased force must be applied.
Note
♦ When closing the door it must lock completely without using

additional force and must have no play.
♦ When adjusting the locking clamp, the door must not be press‐
ed upwards or downwards.
The locking clamp is used for adjusting the following:

• If the front door adjustment is not flush with the rear door or
the side part.
– Slacken the locking clamp -1- by loosening the screws -2- at
the B pillar.
– Adjust the door with the locking clamp -2- in such a way that
the front door when in the closed state is flush with the rear
door (wind noise).
– Tighten screws - 2 - of locking clamp - 1 -.
1. Front door 51
2 Door internal parts
2.1 Front door - Summary of components
1 - Door
page 47 .
❑ Setting
ment”, page 49 .
2 - Clamp
stalling bearing brack‐
et”, page 67 .
3 - Cover for bearing bracket
4 - Cap of lock cylinder
stalling cap for lock cyl‐
inder”, page 57 .
5 - Supporting plate
6 - Outer door handle
stalling the door han‐
dle”, page 63 .
7 - Lock cylinder
stalling lock cylinder”,
page 57 .
8 - External window channel
strip
⇒ “2.16 Removing and
installing the outer win‐
dow channel strip”, page 81 .
9 - Adhesive pad
10 - Screw
❑ Tightening torque - 2.2 Nm.
11 - Screw
12 - Cap
❑ Removing and installing ⇒ “2.2 Removing and installing the door cover”, page 53 .
13 - Outside door seal
❑ Removing and installing ⇒ “2.18 Removing and installing the outside door seal”, page 84 .
14 - Loudspeaker
15 - Cap
❑ Self-adhesive.

❑ If a speaker was not installed.
16 - Nut
17 - Riveted nuts
18 - Inner window channel strip
❑ Removing and installing ⇒ “2.15 Removing and installing the inner window channel strip”, page 80 .
2.2 Removing and installing the door cover
2.2.1 Removing
– Remove front door trim panel

⇒ “2.1 Removing and installing the front door trim panel”, page
257 .
– Lift off the cover -1- in the bottom area.
– Pull the cover - 1 - downwards and remove it from the door
- 5 -.
2. Door internal parts 53

Note
♦ If the following operations are necessary, pull the Bowden cable -2- with the grommet -4- out of the cover
-1-.
♦ The cables are slackened in the holders -3-.
Installing
2.2.2 Removing and installing the door retaining strap
Removing
– Remove the loudspeaker.
– Remove the screw - 2 - at the A pillar.
– Remove the screws -3- and take out the door retaining strap
-1- through the opening after the loudspeaker.
Installing
– Push the door retaining strap through the opening for the loud‐
speaker.

– Install screws - 3 -, tightening torque

– Install screws - 2 -, tightening torque
– Install loudspeaker.
2.2.3 Removing and installing the locking

clamp
Removing
– Release screws - 2 - and remove locking clamp - 1 -.
Installing
– Position locking clamp -1- on the B-pillar -3- and tighten the
screws -2-, tightening torque - 20 Nm.
– Adjusting the locking clamp
2.3 Door handle and door lock - Summary of components

1 - Door lock
stalling the door lock”,
page 65 .
2 - Screw
❑ For lock cylinder.
❑ Tightening torque - 3.5
Nm.
3 - Clamp
et”, page 67 .
4 - Lock cylinder
stalling lock cylinder”,
page 57 .
❑ A lock cylinder is located
only on the driver's door.
5 - Washer
6 - Cap
❑ Remove and install with
lock cylinder
stalling cap for lock cyl‐
inder”, page 57 .
❑ Remove and install
without lock cylinder
stalling cap (without lock
cylinder) ”, page 60 .
7 - Door handle
❑ Removing and installing ⇒ “2.7 Removing and installing the door handle”, page 63 .
8 - Screw
❑ The bearing bracket is released from the door by loosening the screw.
9 - Control cable
❑ From door lock to bearing bracket.
10 - Control cable
❑ From inner door control to lock release.
❑ With grommet for feeding through at the cover.
11 - Screw
12 - Cap

2.4 Removing and installing cap for lock cyl‐

inder
2.4.1 Removing
Note
When removing the cap for the lock cylinder, do not turn or lever
the screwdriver.

– Detach door handle.
– Press a small screwdriver -3- slightly -arrow a- into the opening
on the bottom side of the cap for the lock cylinder.
– Slightly pull off the cap of the lock cylinder -1- , together with
the screwdriver, at the bottom side from the door -arrow b-.
– Slide the cap upwards from the lock cylinder.
2.4.2 Installing
– Remove door handle - 1 -.
– Place the cap of the lock cylinder -2- slightly angled from the
top -arrow a- onto the lock cylinder.
– Press the cap of the lock cylinder -2- onto the door -arrow b-,
until the cap with the lock cylinder locks into position.
2.5 Removing and installing lock cylinder
Note
A lock cylinder is installed only on the driver's door.

2.5.1 Removing
• The cap for the lock cylinder is removed

⇒ “2.4 Removing and installing cap for lock cylinder”,
page 57 .
– Lift off the covers -4 and 6-.
– Remove the screw until it stops -7- so that it exposes the lock
cylinder.
– Remove door handle - 2 -.
– Pull the lock cylinder housing -1- out of the bearing bracket
-3- at a right angle -arrow b- to the door.

2.5.2 Installing
– Remove door handle -2- -arrow a-.

– Fit the lock cylinder housing -1- at a right angle -arrow b- into
the bearing bracket -3-.
– Screw the screws -5 and 7- into the bearing bracket.
– Tightening torque of screws -5 and 7- (3.5 Nm).
Note
During the assembly the lock cylinder housing must be pressed against the outer door panel.

• Then it is absolutely necessary to perform a functional check
when the door is opened.

2.6 Removing and installing cap (without

lock cylinder)
2.6.1 Removing
– Remove the plugs -2- of the rear openings.

– Guide the assembly tool - T10389- by approx. 55 mm into the
door behind the lock hooks -3- of the bearing bracket.
– Pull the assembly tool - T10389- as far towards the rear
-arrow-, until the hook unlocks.

– Detach the door handle -2- in -direction of arrow a- from the

door.
– Pull the cap - 1 - out of the bearing bracket -arrow b-.
2.6.2 Installing
door.
– Push the cap -1- into the bearing bracket -arrow b-.

– Guide the screwdriver -4- at the lock hook -3- of the bearing
bracket.
– Press the cap -1- on the door.
– Press in the screwdriver -arrow- until the hook locks.
– Attach plug -5-.

2.7 Removing and installing the door handle
2.7.1 Removing
Volkswagen Technical Site: http://vwts.ru http://vwts.info

– Remove the lock cylinder
⇒ “2.5 Removing and installing lock cylinder”, page 57 or the
cap
⇒ “2.6 Removing and installing cap (without lock cylinder) ”,
page 60 .
– Pull the door handle -1- slightly towards the rear -arrow a- out
of the support of the bearing bracket.
– Swivel the door handle in -direction of arrow b-.
– Remove the door handle at a right angle -arrow a- out of the
bearing bracket -2-.

2.7.2 Installing
– Fit the door handle -1- at a right angle -arrow b- into the bearing
bracket.
– Swivel the door handle -1- into the door -arrow b-.
– Forcefully press the door handle forwards -arrow c- into the
support of the bearing bracket.
Install the lock cylinder
⇒ “2.5 Removing and installing lock cylinder”, page 57 or the cap
⇒ “2.6 Removing and installing cap (without lock cylinder) ”, page
60 .

2.8 Removing and installing the door lock
2.8.1 Removing

⇒ “2 Door and side trim panels”, page 257 .
– Remove the cover
⇒ “2.2 Removing and installing the door cover”, page 53 .
– Unclip cap - 3 -.
– Unplug connector -4-.
– Remove lock cylinder
⇒ “2.5 Removing and installing lock cylinder”, page 57 .
– Remove the lock -1- from the door.

Note
If it is necessary for the following operations, it is possible to slacken the Bowden cable.
Slacken Bowden cable to bearing bracket

– Twist the Bowden cable -5- by 45° and remove it from the
bracket -arrow a-.
– Turn the Bowden cable - arrow b -until it can be guided out of
the lug in the door lock (Pos. 1) - arrow c -.
Slacken the Bowden cable to the inner door control:
bracket.
– Turn the Bowden cable -arrow d- until it can be guided out of
the lug in the door lock (Pos.1) -arrow e-.
2.8.2 Installing
Installing

– Tightening torque of screw (Pos. 2) - 20 Nm.

It is absolutely necessary to perform a functional check because
the door cannot be opened if the adjustment of the Bowden cables
is not accurate and if they are not correctly locked.
2.9 Removing and installing bearing bracket
2.9.1 Removing

– Remove the lock cylinder
⇒ “2.5 Removing and installing lock cylinder”, page 57 or the
cap
⇒ “2.6 Removing and installing cap (without lock cylinder) ”,
page 60 .
– Removing the door handle
⇒ “2.7 Removing and installing the door handle”, page 63 .

– Release screw - 4 - and remove gasket - 3 -.

– Take the bearing bracket -1- out of the door -arrow a-.
Slacken Bowden cable
– Unlock the bracket -5- and swivel out of the support in the
bearing bracket -arrow b-.
– Lift the bolt of the control cable out of the support -arrow c-.
– Take the control cable -2- out of the bearing bracket (Pos.1)
-arrow d-.
2.9.2 Installing
The installation occurs in reverse order.

– Install screw -2-, tightening torque 1.5 Nm.

2.10 Front door window
1 - Door window
installing door window”,
page 70 .
2 - Window lifter
⇒ “2.13 Remove and in‐
stall window lifter”, page
76 .
3 - Nut
Nm.
4 - Door
5 - Window lifter motor
installing window lifter
motor”, page 74 .
6 - Screw
Nm.
7 - Window run
❑ Fitted on the flange.
installing the window
run”, page 77 .
8 - Retaining clip

2.11 Removing and installing door window
2.11.1 Removing

257 .
– Release cap - 4 -.
– Remove cover -5-
– Lower the door window - 1 - so that the catches - 2 - are visible
in the openings on the impellers of the runners - 3 -.
– Press the catch at the point of the -arrow- towards the inside
and thereby unlock the door window - 2 - using for example a
screwdriver. Perform the same at the second catch.

Note
♦ If this operation cannot be performed due to a failure at the power-window lifter, remove the motor
⇒ “2.12 Removing and installing window lifter motor”, page 74 (depending upon vehicle equipment).
♦ Then the door window can be pushed to the required working height.
– Lift up the door pane - 1 - at the rear and swivel it forwards out
of the window run - 2 - in - direction of arrow -.

2.11.2 Installing
– Insert the door window - 1 - into the window run - 2 - in

- direction of arrow a -.
Note
Ensure that the door window is correctly inserted in the window run.
– Guide the door window pressureless into the clamping jaws

-arrow b-.
– Align the door window to the window frame -arrow c-.

– Apply gentle pressure to both sides of the door window while

pressing evenly into the catches until it audibly locks into
place.
– Subsequently proceed in reverse order to removing.
• A functional check must be performed before installing the
door trim panel.

2.12 Removing and installing window lifter

motor
2.12.1 Removing

257 .
– Secure the door window with adhesive tape so that it does not
slide off.
– Remove the window lifter motor with the control unit - 1 - from
the supports - 3 -.

2.12.2 Installing
WARNING
On a new window lifter motor (door control unit), the auxiliary

functions must be coded.
– Fit the window lifter motor - 1 - into the supports - 3 -. Raise

the door window and then lower it so that the serration can
slide in better between the motor and the cable drum.
– Install screws -2-, 3 Nm.
– Secure the plug connection - 4 -.
– Code the new window lifter motor.
– The further work procedure occurs in the reverse order to the
removal.

2.13 Remove and install window lifter
2.13.1 Removing

257 .
– Remove door window
⇒ “2.11 Removing and installing door window”, page 70 .
– Remove window lifter motor
⇒ “2.12 Removing and installing window lifter motor”,
page 74 .
– Unlock the catches of the hoisting drum -arrows d- and fit them
into the door.
– Slide the window lifter -1- into the door and slightly turn it in
-direction of arrow a-.
– Remove the window lifter through the door cutout -arrow b-
and -arrow c-.

2.13.2 Installing
– Insert the window lifter -2- through the door cutout -arrow a-.
– Put the window lifter in its fitting position -arrow b-.
– Insert the window lifter thread through the door openings
-arrow c- and tighten the nuts -4-. Tightening torque - 8 Nm.
– Press the hoisting drum -1- through the holes in the door until
the catch hooks -arrow d- lock.
2.14 Removing and installing the window run
Note
Do not bend the window seal while removing!

2.14.1 Removing
The exterior mirror and the window channel strip are removed.
– Pull out the retaining clip (Pos. 3) - arrow c -.
– Push away the sealing lip of the window run from the inside
out of the door flange.
– Detach the window run -1- evenly all around -arrows a- from
the door flange -2-, starting in the rear area.
– Pull the window run -1- out of the supports -arrows b-.

2.14.2 Installing
Note
Before assembly the gasket contact surfaces must be coated with soapy water so that they can be moved easily
and positioned on the flanges more accurately.
– Mask off the openings -4- below the window guide with fabric
adhesive tape.
– Dimensions of adhesive: height = approx. 10 mm, width = ap‐
prox. 40 mm.
– Slide the window run into the supports -arrows a-.
– Press the window run evenly all around against the door flange
-2-.
– Press the sealing lip of the door run from the inside against the
door flange.
– Push in the retaining clip (Pos. 3) - arrow b -.

Note
♦ The chamfer of the retaining clips must point to the inside of the vehicle.
♦ If the chamfer of the retaining clips points to the outside of the vehicle, the -crossed-out red colour-, then
the retaining clip must be turned around.

door trim panel.
Note
Pay attention to evenly fitting the window run when installing it (wind noise).
2.15 Removing and installing the inner window channel strip
Removing
257 .

– Remove gasket -1- evenly -arrows- without bending the flange

-2-.
Installing
Press the window channel strip - 1 - by hand evenly onto the
flange - 2 -.
2.16 Removing and installing the outer win‐

dow channel strip
2.16.1 Removing
Note
♦ The core of the seal consists of a metal insert.

♦ If it is bent, the seal can no longer be straightened. It remains
“warped”.
♦ Therefore the seal must be fitted on uniformly and without
bending it.

– Remove the seal -1- uniformly -arrows b- out of the door -2-
up to the exterior mirror.
– Pull out the seal from underneath the exterior mirror
-arrow a-.
2.16.2 Installing
– Slide the seal under the exterior mirror -arrow b-.

– Press the seal -1- uniformly -arrows a- by hand onto the flange
-2-.
2.17 Removing and installing the inside door

seal
During the installation in series, the inside door seals are provided
with a sealing compound which is placed on the door flange and
subsequently rolled up.

Note
♦ During the removal of the seal, the sealing mass is distributed

on the inside of the seal. While doing so, the sides are slightly
bent open. If the seal is re-installed, leak-tightness and tight fit
can no longer be guaranteed.
Removing
– Remove the trim panels of the pillars for removing the inside
door seal ⇒ “3 Trim panels of pillars”, page 263 .
– Remove sill
⇒ “3.8.1 Removing and installing door sill panel”, page 271 .
– Detach the inside door seal -1- from the body flange.

Installing
– Align the inside door seal -1- with the vulcanization point
-arrow b- at the top bonnet hinge -arrow b-.
– When installing the inside door seal, start in the top radius of
the door cutout -arrow a-.
2.18 Removing and installing the outside door seal
Removing
– Unclip the outside door seal -1- with the clips -2- from the door
-3-.
Installing
– Press the seal - 1 - with the clips - 2 - on the door.
Note
Check the bracket -2- for damage, and replace where necessary.

3 Central locking
Note
The control motors of the front and rear doors central locking are
component parts of the door locks and cannot be replaced indi‐
vidually.
– Removing and installing the door lock

⇒ “2.8 Removing and installing the door lock”, page 65 .
– After replacing the door lock with central locking motor, inter‐
rogate the event memory and erase ⇒ Vehicle diagnostic
tester Self-Diagnosis for Convenience System.
3.1 Adjustment of radio control keys

3.2 Summary of components – battery for the (foldable) radio control key
1 - Key with transponder alter‐

nating code
2 - Radio container - top part
3 - LED
❑ This LED must flash
when operating the ra‐
dio remote control.
❑ If the LED does not flash
when operating the ra‐
dio remote control, the
battery is discharged
and must be changed.
4 - Battery
stalling the battery for
the foldable key with ra‐
dio remote control ”,
page 86 .
5 - Radio container - bottom
part
3. Central locking 85
3.3 Removing and installing the battery for

the foldable key with radio remote con‐
trol
– Key shape of the foldable radio remote control key (Pos.1).
Removing
– Insert a screwdriver under the catch in -direction of arrow- and

lever the battery cover (Pos. 1) off the key (Pos. 2).
– Unclip the battery (Pos. 2) from the catches using a screw‐

driver.
Installing
Note
♦ Before installing the battery, it is absolutely necessary to press

a random button once. Thus, the radio container is reset to as-
new condition and can only now detect a new battery.
♦ Observe the polarity and the fitting location when installing the
battery.
– Insert the battery on the provided point and press slightly until
it locks into position between the contacts.
– Clip in the battery cover.

58 – Rear doors, door components

1 Rear door
1.1 Assembly overview - door hanger
Note
Always replace the screws for the door hinges after slackening.
1 - Door
page 89 .
❑ Setting
ment”, page 91 .
❑ 32 Nm.
al.
3 - Door hinge
❑ The top part is connec‐
ted to the bottom part of
the hinge by the screw
- 4 -.
4 - Screw
❑ This screw must be un‐
screwed in order to re‐
move the door from the
hinge.
❑ 23 Nm.
❑ Installed from the inside
of the vehicle.
❑ Remove bottom trim
panel of B pillar
stalling bottom B-pillar
trim panel”, page 267 .
❑ 32 Nm.
screws after the removal.
6 - Door hinge
❑ 32 Nm.
1. Rear door 87
8 - Screw
❑ 32 Nm.
❑ 30 Nm - only for Russian market
❑ This screw must be unscrewed in order to remove the door.
9 - Door retaining strap
10 - Screw
❑ 9 Nm.
❑ For door retaining strap.
❑ Installed from the inside of the vehicle.
❑ 32 Nm.
12 - Door hinge
❑ 32 Nm.
❑ 32 Nm.
15 - Door hinge
❑ The top part is connected to the bottom part of the hinge by the screw - 16 -.
16 - Screw
❑ 23 Nm.
❑ This screw must be screwed down in order to remove the door from the hinge bolt.
88 Rep. gr.58 - Rear doors, door components

1.2 Removing and installing the door
1.2.1 Removing
– Release the bellows -2- by pressing on the catch -arrow a- and

detach it from the A pillar.
– Swivel the release lever -3- downwards -arrow b- and discon‐
nect the el. plug connection -4- from the connector station.
– Slacken the screws -7- at the hinges -arrows d-.
– Remove the screws -5- for the door retaining strap -6-.
– Pull the door -1- upwards -arrow e- and out of the hinges -8-.
1. Rear door 89
1.2.2 Installing

– Tightening torques of screws
⇒ “1.1 Assembly overview - door hanger”, page 87 .
– Observe the gap sizes of the front door ⇒ Body Repairs; Rep.

1.3 Door adjustment
Note
♦ The vehicle must be standing on its wheels in order to adjust

the rear door.
♦ The rear door is correctly adjusted if in the closed state it has
an overall even gap size, is not positioned too far inwards or
outwards and the contours are aligned.
♦ Observe the gap sizes of the front door ⇒ Body Repairs; Rep.
♦ After carrying out adjustment work, perform corrosion protec‐
tion measures at the screws and hinges.

In order to correctly set the gap sizes, the screws
-2, 5, 7, and 8- must be slackened at the A pillar.
– The bottom B pillar trim panel must be removed for the screw
-5-
1. Rear door 91
⇒ “3.5 Removing and installing bottom B-pillar trim panel”,

page 267 .
– The bottom B pillar trim panel must be removed for the screw
-7-
page 267 .
Slacken the screws -3 and 9- for correctly setting the flushness.
Note
Other measures, such as aligning the doors towards the top are ineffective. The door will drop again at the
following overpressures.
Adjusting the locking clamp


Note
♦ To adjust the locking clamp -2- once the screws -3- are loosened, increased force must be applied.
♦ When closing the door it must lock completely without using additional force and must have no play.
♦ When adjusting the locking clamp, the door must not be pressed upwards or downwards.
The locking clamp is used for adjusting the following:

• If the rear door adjustment is not flush with the side part.
– Slacken the locking clamp -1- by loosening the screws -2- at
the C pillar.
– Adjust the door with the locking clamp -1- in such a way that
the rear door when in the closed state is flush with the side
part (wind noise).
– Tighten screws - 2 - of locking clamp - 1 -.
Tightening torque of screws (Pos. 2) - 20 Nm.
1. Rear door 93
2 Door internal parts
1 - Door
page 89 .
❑ Setting
ment”, page 91 .
2 - Cover for bearing bracket
3 - Bearing bracket
et”, page 106 .
4 - Supporting plate
5 - Outer door handle
dle”, page 102 .
6 - Cap
stalling the cap”,
page 99 .
7 - Screw
Nm.
8 - Nut
Nm.
9 - Riveted nuts
10 - Door lock
❑ Removing and installing ⇒ “2.8 Removing and installing the door lock”, page 104 .
11 - Screw
12 - Cover
❑ Removing and installing ⇒ “2.2 Removing and installing the cover”, page 95 .
13 - Outside door seal
❑ Removing and installing ⇒ “2.22 Removing and installing the outside door seal”, page 125 .
14 - Loudspeaker
15 - Cover
❑ Self-adhesive.
❑ If a speaker was not installed.

16 - Inner window channel strip

❑ Removing and installing ⇒ “2.19 Removing and installing the inner window channel strip”, page 121 .
17 - External window channel strip
❑ Removing and installing ⇒ “2.20 Removing and installing the outer window channel strip”, page 123 .
2.2 Removing and installing the cover
2.2.1 Removing
– Removing door trim panel

⇒ “2.2 Removing and installing the rear door trim panel ”, page
259 .
– Lift off the cover -1- in the bottom area.
– Pull the cover - 1 - downwards and remove it from the door
- 4 - in -direction of arrow-.

Note
♦ If the following operations are necessary, pull the Bowden cable -2- with the grommet -3- out of the cover
-1-.
♦ The cables are slackened in the holders -5-.
2.2.2 Installing
– Pull the Bowden cable -2- through the cover -1- and secure
the grommet -3-.
– Insert the cover - 1 - upwards into the door - 4 -.
– Press the cover at the bottom in the door.
Note
The cables are secured in the holders - 5 -.

2.3 Removing and installing the door retaining strap
Removing
– Remove the loudspeaker.
– Remove the screw - 2 - at the A pillar.
– Remove the screws -3- and take out the door retaining strap
-1- through the opening after the loudspeaker.
Installing
– Fit the door retaining strap - 1 - through the opening after the
loudspeaker.
– Tighten screws -3-. Tightening torque
– Tighten bolt -2-. Tightening torque

2.4 Removing and installing the locking

clamp
Removing
– Release screws - 2 - and remove locking clamp - 1 -.
Installing
– Fit the locking clamp - 1 - at the D pillar and position the screws
- 2 -. Tightening torque - 25 Nm.
– Adjusting the locking clamp
2.5 Door handle and door lock - Summary of components
1 - Door lock
stalling the door lock”,
page 104 .
2 - Control cable
❑ From inner door control
to lock release.
3 - Control cable
❑ From door lock to bear‐
ing bracket.
4 - Clamp
stalling the locking
clamp”, page 98 .
5 - Screw
Nm.
❑ The bearing bracket is
released from the door
by loosening the screw.
6 - Door handle
dle”, page 102 .
7 - Cap
stalling the cap”,
page 99 .
8 - Washer
9 - Cover
❑ Not installed in all the countries.
10 - Screw

2.6 Removing and installing the cap
2.6.1 Removing
– Remove the plugs -2- from the rear openings.

– Guide the assembly tool - T10389- by approx. 38 mm into the
opening behind the lock hooks -3- of the bearing bracket.
– Pull the assembly tool - T10389- as far towards the rear
-arrow-, until the hook unlocks.


door.
– Pull the cap - 1 - out of the bearing bracket -arrow b-.
2.6.2 Installing
door.
– Push the cap -1- into the bearing bracket -arrow b-.

– For example guide a screwdriver -4- at the lock hooks -3- of

the bearing bracket.
– Press the cap -1- on the door.
– Press in the screwdriver -arrow- until the hook locks.
– Attach plug -5-.

2.7 Removing and installing the door handle
2.7.1 Removing
– Remove the cap

⇒ “2.6 Removing and installing the cap”, page 99 .
– Pull the door handle -1- slightly towards the rear arrow -a- out
of the support of the bearing bracket.
– Swivel the door handle in -direction of arrow b-.
– Remove the door handle at a right angle -arrow a- out of the
bearing bracket -2-.

2.7.2 Installing
– Fit the door handle -1- at a right angle -arrow b- into the bearing
bracket.
– Swivel the door handle -1- into the door -arrow b-.
– Forcefully press the door handle forwards -arrow c- into the
support of the bearing bracket.
Install the cap
⇒ “2.6 Removing and installing the cap”, page 99 .

2.8 Removing and installing the door lock
2.8.1 Removing
– Remove rear door trim panel

259 .
⇒ “2.2 Removing and installing the cover”, page 95 .
– Remove the lock - 1 - from the door - 2 -.
Slacken Bowden cable to bearing bracket
bracket -arrow a-.
– Turn the Bowden cable - arrow b -until it can be guided out of
the lug in the door lock (Pos. 1) - arrow c -.

Slacken the Bowden cable to the inner door control:

bracket.
– Turn the Bowden cable - arrow d - until the Bowden cable can
be guided out of the lug in the door lock (Pos.1) - arrow e -.
2.8.2 Installing

– Tightening torque of screw (Pos. 4) - 18 Nm.
It is absolutely necessary to perform a functional check because
the door cannot be opened if the adjustment of the Bowden cables
is not accurate and if they are not correctly locked.

2.9 Removing and installing bearing bracket
2.9.1 Removing

259 .
⇒ “2.2 Removing and installing the cover”, page 95 .
– Remove the cap
⇒ “2.6 Removing and installing the cap”, page 99 and the door
handle
⇒ “2.7 Removing and installing the door handle”, page 102 .
– Release screw - 4 - and remove gasket - 3 -.
– Take the bearing bracket -1- out of the door -arrow a-.
Slacken Bowden cable
– Unlock the bracket -5- and swivel the bracket out of the support
in the bearing bracket -arrow b-.
– Lift the bolt of the control cable out of the support -arrow c-.

– Remove the Bowden cable from the bearing bracket

- arrow d - .
2.9.2 Installing

– Install screw -2-, tightening torque 1 Nm.

2.10 Rear door window
1 - Door window
installing door window”,
page 109 .
2 - Window run
❑ Inserted in the flange.
installing the window
run”, page 117 .
3 - Fixed door window
installing the rear fixed
door window”,
page 120 .
4 - Window lifter
⇒ “2.15 Remove and in‐
stall window lifter”, page
116 .
5 - Nut
Nm.
6 - Screw
Nm.
7 - Window crank
❑ For manual operation.
installing window
crank”, page 115 .
8 - Manual drive
❑ Removing and installing ⇒ “2.13 Removing and installing the manual drive”, page 114 .
9 - Window lifter motor
❑ Removing and installing ⇒ “2.12 Removing and installing window lifter motor”, page 112 .
10 - Adjusting pin and straddling dowel
❑ For securing the door window.

2.11 Removing and installing door window
2.11.1 Removing

259 .
– Remove inside door seal
⇒ “2.19 Removing and installing the inner window channel
strip”, page 121 .
– Release cap - 5 -.
– Lower the door window -6- until the expanding pin -4- and the
straddling dowel -3- can be accessed in the window lifter
opening -2-.
Note
If this operation cannot be performed due to a failure at the window lifter motor, remove the window lifter motor
-7-. Then the door window can be pushed to the required working height.

– Screw a 5 mm screw (approx. 70 mm long) into the adjusting

pin - 4 - and pull the adjusting pin from the straddling dowel
- 3 -.
– Screw an 8 mm screw (approx. 80 mm long) into the straddling
dowel -3- and pull out of the pane.
Note
Do not use excessive force when screwing the screw into the straddling dowel as it may fall into the door.
– Withdraw the straddling dowel - 3 - from the window lifter guide

- 1 - and hence from the door window.
Note
Hold the door window when pulling out the straddling dowel so that the door does not fall down and get dam‐
aged.
– Pull the rear part of the window run -2- out of the supports.

– Pull the door window - 1 - upwards at an angle - arrows - to‐

wards the outside of the vehicle and out of the window chan‐
nel.
2.11.2 Installing
Note
Before inserting the expanding dowel - 3 - and the expanding pin

- 4 -, check the door window - 1 - for damage.
– Take the mean of the centre straddling dowel - 3 - and insert

it when the door window is removed - 1 -.
– Press the straddle pin -4- into the straddling dowel -3-.
– Guide the pane - 1 - into the door - 2 - - arrows a - and insert
the window lifter guide - 5 -.
– Gently tap on the pane - 1 - to lock it from above into the win‐
dow lifter - 5 -.
– It must be pressed until the catch locks audibly into place.


removal.
door trim panel.
2.12 Removing and installing window lifter

motor
2.12.1 Removing

259 .
slide off.
– Remove the window lifter motor with the control unit - 1 - from
the supports of the hoisting drum - 3 -.

2.12.2 Installing
WARNING
On a newly installed window lifter motor (door control unit), the

auxiliary functions must be coded!
– Fit the window lifter motor - 1 - on the supports of the hoisting

drum - 3 -. Raise the door window slightly and then lower it so
that the serration can slide in better between the motor and
the cable drum.
– Install screws -2- (3 Nm).
– Secure the plug connections - 4 -.
– The new window lifter motor is coded.
removal.

2.13 Removing and installing the manual drive
Removing
– Remove window crank
⇒ “2.14 Removing and installing window crank”, page 115 .
259 .
slide off.
– Remove the manual drive - 1 - from the supports of the hoisting
drum - 3 -.
Installing
– Fit the manual drive - 1 - on the supports of the hoisting drum
- 3 -. Raise the door window slightly and then lower it so that
the serration can slide in better between the manual drive and
the hoisting drum.


removal.
2.14 Removing and installing window crank
Removing
– Press together the circlip -2- -arrows a-.
– Pull the circlip - 2 - a little from below the window crank (Pos.
1) - arrow b - .
– Pull off window crank -1- -arrow c-.
Installing
– Insert circlip - 2 -.
– Press on window crank - 1 -.

2.15 Remove and install window lifter
2.15.1 Removing

259 .
– Remove door window
– Remove window lifter motor or manual drive
⇒ “2.12 Removing and installing window lifter motor”,
page 112 .
– Unlock the catches -4- of the hoisting drum -3- and slide them
into the door -arrows a-.
– Slide the window lifter - 1 - into the door.
– Slide the window lifter to the door cutout -arrow b- and take it
out -arrow c-.

2.15.2 Installing
– Insert the window lifter -1- through the door cutout -arrow a-.
– Put the window lifter in its fitting position -arrow b-.
– Push the window lifter thread through the door and tighten the
nuts - 2 - (6 Nm).
– Press the hoisting drum through the door openings
-arrows c-, until the catches lock into position.
2.16 Removing and installing the window run
Note
♦ Before assembly the gasket contact surfaces must be coated

with soapy water so that they can be moved easily and posi‐
tioned on the flanges more accurately.
♦ Do not bend the window run when removing!

2.16.1 Removing the window run
– Take the window run seal -1 - from the inside out of the window
frame.
– Pull the window run -1- out of the supports in the door
-arrows b-.
– Loosen both retaining clips -3- of the seal -1- from the door.
– Detach the seal -1- evenly -arrows a- from the door flange.

2.16.2 Installing
– The openings -4- under the window run must be masked with
fabric adhesive tape.
Dimensions of adhesive: height = approx. 10 mm, width = approx.
40 mm. 2 pieces.
– Slide the window run -1- into the supports -arrows a-.
– Press the window run -1- evenly all around against the door
flange -2-.
– Press the sealing lip of the door run from the inside against the
door flange.
– Slide in the retaining clip -3- -arrow b-.
Note
♦ The chamfer of the retaining clips must point to the inside of the vehicle.
♦ If the chamfer points to the outside of the vehicle, the -crossed-out red colour-, then the retaining clip must
be turned around.


door trim panel.
2.17 Removing and installing the rear fixed

door window
Removing
– Remove rear door window
– Remove outer seal
⇒ “2.20 Removing and installing the outer window channel
– Mask off the protective foil from the bolt holes -2-.
– Partly remove window run
⇒ “2.16 Removing and installing the window run”, page 117 .
– Slide the seal on the inside of the fixed door window below the
leg of the door frame so that the tools can be inserted on the
provided point.
– Insert the tool T30116 - 3 - between the pane and the door
frame towards the unlocking bolt (in position as shown in the
illustration).
– Detach the fixed pane -1- slightly after releasing from the door
frame.
frame towards the unlocking bolt (in position as shown in the
illustration).
frame.
– Carefully push the fixed pane out of the door frame.
Installing
– Insert the fixed pane into the door frame.
– Insert the securing bolts into the openings in the door frame
and clip in.
– Push the seal of the fixed pane over the door frame and cor‐
rectly insert the pane.
– Stick over protective foil with bolt holes -2-.
removal.
Note
The securing bolts are component parts of the fixed pane. In case
of damage, the fixed pane must be completely replaced.
2.18 Removing and installing the rear fixed

door window (Spaceback)
Removing
– Remove rear door window

– Remove outer seal

⇒ “2.20 Removing and installing the outer window channel
– Mask off the protective foil from the bolt hole -3-.
– Partly remove window run
⇒ “2.16 Removing and installing the window run”, page 117 .
– Slide the seal on the inside of the fixed door window below the
leg of the door frame so that the tools can be inserted on the
provided point.
frame towards the first unlocking bolt (in position as shown in
the illustration).
frame.
frame towards the second unlocking bolt (in position as shown
in the illustration).
frame.
– Carefully push the fixed pane out of the door frame.
Installing
– Insert the fixed pane into the door frame.
– Insert the securing bolts into the openings in the door frame
and clip in.
– Push the seal of the fixed pane over the door frame and cor‐
rectly insert the pane.
– Screw in screw - 3 - (6 Nm).
– Stick protective foil over bolt hole - 3 -.
removal.
Note
The securing bolts are component parts of the fixed pane. In case
of damage, the fixed pane must be completely replaced.
2.19 Removing and installing the inner window channel strip

Removing
259 .
– Detach window channel strip - 1 - evenly - arrows - from the
flange - 2 -.
Installing
– Press the window channel strip - 1 - by hand evenly onto the
flange - 2 -.

2.20 Removing and installing the outer win‐

dow channel strip
Note
♦ The core of the seal consists of a metal insert. If it is bent, the

seal can no longer be straightened. It remains “warped”.
♦ Therefore the seal must be removed uniformly and without
bending it.
Removing
– Detach window channel strip - 1 - evenly - arrows - from the
flange - 2 -.
Installing
– Press the window channel strip - 1 - by hand evenly onto the
flange - 2 -.

2.21 Removing and installing the inside door

seal
During the installation in series, the inside door seals are provided
with a sealing compound which is placed on the door flange and
subsequently rolled up.
Note
♦ During the removal of the seal, the sealing mass is distributed

on the inside of the seal. While doing so, the sides are slightly
bent open. If the seal is re-installed, leak-tightness and tight fit
can no longer be guaranteed.
♦ Removing and installing is only carried out for the right inside
door seal. The same applies therefore when removing and in‐
stalling the left inside door seal.

Removing
– Remove trim panels of pillars
⇒ “3 Trim panels of pillars”, page 263 .
– Detach the inside door seal - 1 - from the body flange - 2 -.
Installing
– When installing the inside door seal, start in the top radius of
the door cutout -arrows b-.
– Sealing joint at the point -arrows a-.
2.22 Removing and installing the outside

door seal
Note
Check the bracket -2- for damage, and replace where necessary.
Removing
– Unclip the clips - 2 - and remove the seal - 1 - from the door
- 3 -.

Installing
– Press the seal - 1 - with the clips - 2 - on the door.
Note
The seal - 1 - must rest directly at the seal of the window run.

60 – Sunroof
1 Panoramic roof
1.1 Summary of components of panoramic roof
1 - Window of panoramic roof

2 - Glue sealing material
3 - Gasket all the way around
4 - Body sheet profiles
5 - Fixing bolts
1.2 Removing and installing panoramic roof
WARNING
Wear protective goggles and gloves when cutting hardened

PUR glue sealing material and when working with window and
cutting cords.
Panoramic roof cannot be used again after being cut out. The
all-round seal is damaged when cutting which cannot be re‐
placed. At the same time, the moulding on the contact surface
of the panoramic roof is also damaged.
1. Panoramic roof 127

Note
A second mechanic is required for removing and installing.

♦ Separating device for glued windows (set), e.g. -V.A.G 1474/
A- .
♦ Straightening knife e.g. -SB - 531- or glass scraper -SC - 170- .
♦ Cutting tool e.g. -V.A.G 1351- .
♦ Piercing needle e.g. -V.A.G 1474/2- .
♦ Cutting cord e.g. -357 845 955- .
♦ Cutting wire e.g. -357 853 999 B- .
♦ Cup suction tool e.g. -V.A.G 1344- .
♦ Cartridge heating box e.g. -V.A.G 1939A- .
♦ Compressed air pistol, e.g. -VAS 5237- .
Removing
– Remove the moulded headliner
⇒ “7 Moulded headliner”, page 282 .
– Cover the painted surfaces along the window with textile ad‐
hesive tape or protective film e.g. -V.A.G 1474/7- .
– Pierce glue sealing material with piercing needle in the rear
corner.
– Pull through cutting cord and fasten the ends in the “ T ” hold‐
ers.
– Cut through glue sealing material around the window.
– Remove window with the aid of suction cups.
Install panoramic roof
– Prepare flange for panoramic roof
⇒ “1.13 Prepare body flange for fitting”, page 155 .
– Prepare adhesive surface of the new panoramic roof
⇒ “1.12.2 Prepare new window for fitting ”, page 154 .
– Glue sealing materials ⇒ “3 Materials”, page 130 .
– Gluing on
⇒ “1.14 Installation instructions for all panes”, page 155 .
– Waiting time ⇒ “1.15 Minimum hardening time”, page 156 .
128 Rep. gr.60 - Sunroof

2 Removing and installing roof roller

Removing roof roller (front and rear)
⇒ “7 Moulded headliner”, page 282 .
– Slide blind up to the end position.
– Removing fixing screws for roof roller -1-.
– Push roof roller - 2 - out of the runner - 3 -.
– Remove roof roller - 4 -.
Installing
2. Removing and installing roof roller 129

3 Materials
Note
The part numbers of the materials are provided in the ⇒ Electronic

Catalogue of Original Parts - ETKA .
♦ 2K window pane adhesive 1) 1 2) 2 4) 4 6) 6
♦ Activator 1) 1
♦ Glass/paint primer 1) 1
♦ Cleaning solution 1) 1
♦ Primer applicator 1) 1
♦ Adhesive remover 1) 1
1) Observe the handling instructions in accordance with the specifications of the

manufacturer in the package insert.
2) Observe minimum hardening time.
3) According to manufacturer's instructions heat up e.g. with cartridge heater -
V.A.G 1939- .
4) Use for example the double cartridge gun - VAS 5237- for processing this
material.
5) Small cartridges 180 ml for sealing work, or if 400 ml cartridge is not adequate.
6) When using a 2K window pane component adhesive, remove the first 10 cm of
the pressed out adhesive in order to ensure the correct mixture of both compo‐
nents.
130 Rep. gr.60 - Sunroof

63 – Bumpers
1 Front bumper
1.1 Front bumper
Note

into consideration when removing and installing the front bumper.
1 - Screws
Nm.
2 - Screw
3 - Front bumper
❑ Removing
page 132 .
❑ Installing
page 132 .
1. Front bumper 131

1.1.2 Removing
– Remove wheelhouse liners

⇒ “1.1 Front wheelhouse liner”, page 158 .
– Remove screws -1- (1,5 Nm).
– Detach the front bumper from the left and right guide parts on
the wing below the headlights.
– Slacken the bumper on the side guides.
– Detach the front bumper - 3 - parallel from the vehicle with the
assistance of a 2nd mechanic.
ponents.
– Separate the hose connections from the hoses of the cleaning
system (if present) ⇒ Electrical System; Rep. gr. 92 .
1.1.3 Installing
132 Rep. gr.63 - Bumpers

– Be mindful of parallelism and correct gap dimensions for the

front bumper - 1 - ⇒ Body Repairs; Rep. gr. 00 ; Body gap
dimensions; front body .
1.1.4 Front bumper - component parts
1 - Radiator grill
❑ Clipped into the bump‐
er.
2 - Decorative frame
er.
3 - Bumpers
❑ Removing
page 132 .
❑ Installing
page 132 .
4 - Left grid
er.
5 - Left fog light
⇒ Electrical System;
Rep. gr. 94 .
6 - Middle ventilation grid
er.
7 - Right grid
er.
8 - Right fog light
⇒ Electrical System;
Rep. gr. 94 .
9 - Cap
❑ Cover for towing lug.
10 - Bumper mount
1. Front bumper 133

1.2 Front bumper bracket
1 - Front bumper bracket

– Removing front bumper

page 132 .
– Remove impact absorb‐

er.

2 - Screw
Nm.
3 - Screw
Nm.

2 Rear bumper
2.1 Rear bumper
Note

into consideration when removing and installing the rear bumper.
1 - Centre guide section

2 - Nut
Nm.
3 - Nut
Nm.
4 - Bumper bracket (depending
upon vehicle equipment)
Removing
⇒ “2.2 Rear bumper bracket
and runners”, page 137 .
5 - Screw
Nm.
6 - Rear bumper
⇒ “2.1.2 Remove the
rear bumper”,
page 136 .
7 - Lateral guide section
❑ Screwed together with
the side part.
8 - Guide section
Nm.
2. Rear bumper 135

2.1.2 Remove the rear bumper
– Remove tail lights ⇒ Electrical System; Rep. gr. 94 .

– Remove the screws -4- in the area of the left and right wheel‐
house.
– Remove the screws -5- from below.
– Unclip the rear bumper - 1 - out of the catches of the lateral
guides (Pos.3) - arrow b -.
– Carry out further installation only with the assistance of a sec‐
ond mechanic.
– Slacken the catches -arrows a- at the top guides -2-.
– Detach the rear bumper -1- parallel from the vehicle
-arrows c-.
ponents.
2.1.3 Installing the rear bumper

– Attach the existing plug connections.

– Position the rear bumper with the assistance of a second me‐

chanic.
Note
When fitting the rear bumper, make sure to guide it parallel at the
left and right guide sections.
– Press the rear bumper onto the centre guide section and the
left and right guide section until they lock audibly together.
– Observe the parallelism and the correct gap sizes ⇒ Body Re‐
pairs; Rep. gr. 00; Rozměry spár karoserie; zadní část kar‐
oserie .
– Position screws and tighten
⇒ “2.1.1 Summary of components”, page 135 .
2.2 Rear bumper bracket and runners
1 - Centre guide section

Removing
– Remove the rear bump‐

er
rear bumper”,
page 136 .
– Release the nuts

⇒ Item 2 (page 137) .
– Remove the bumper

bracket from the vehi‐
cle.
Installing

in reverse order.
2 - Nut
Nm.
Removing

er
rear bumper”,
page 136 .
– Release the nuts

⇒ Item 4 (page 138) .

cle.
Installing
2. Rear bumper 137

4 - Nut
5 - Impact absorber (depending upon vehicle equipment)
❑ Secured with double-sided adhesive tape.
6 - Nut
7 - Guide section
Removing
– Remove the rear bumper ⇒ “2.1.2 Remove the rear bumper”, page 136 .
– Release the nuts ⇒ Item 6 (page 138) .

– Remove the guide section from the vehicle.
Installing
8 - Screw
Removing
– Remove the rear bumper ⇒ “2.1.2 Remove the rear bumper”, page 136 .
– Release screws ⇒ Item 8 (page 138) .
– Remove the guide section from the vehicle.
Installing

3 Rear bumper (Spacebook)

1 - Spacer sleeve for screw

3 - Screw
– Tightening torque - 2.2
Nm.
4 - Rear guide profile

5 - Nut
– Tightening torque - 2.2
Nm.

Removing

er
rear bumper”,
page 136 .
– Release screws
⇒ Item 12 (page 139) .

cle.
Installing

in reverse order.
7 - Impact absorber (depend‐

ing upon vehicle equipment)
❑ Secured with double-si‐
ded adhesive tape.
8 - Rear reflector
– Clipped into the bumper.
– The removal and installation is possible without removing the bumper.
9 - Spoiler
– Clipped into the bumper.
– Remove the bumper for the removal procedure ⇒ “2.1.2 Remove the rear bumper”, page 136 .
10 - Rear bumper
– Removing and installing ⇒ “2.1.2 Remove the rear bumper”, page 136 .
11 - Screw
– Tightening torque - 2 Nm.
12 - Screw
– Tightening torque - 20 Nm.
3. Rear bumper (Spacebook) 139

4 Cutting out the openings for the park‐

ing aid sensors (drill)
Predrill the openings
Note
Avoid damage to the painted bumper side!
– Removing the bumper ⇒ “2.1 Rear bumper”, page 135 .

– In the area of the sketched out axle crosses, mark the centres
for drilling four openings using a suitable tool.
– Drill the openings with a diameter of 8 mm.

Openings for the sensors

– Use the cutting tool BEA 000 001 to cut out the opening (di‐
ameter 18 mm).
– Use a step drill in order to drill the openings.
– First of all make the openings from the outer side of the bumper
when using a step drill. Complete the work step from the inner
side of the bumper.
– Trim the openings in a suitable manner in order to avoid dam‐
age to the paintwork.
– The glueing procedure of new sensor holders is described in
the workshop manual ⇒ Electrical System; Rep. gr. 94 .
– After installing the sensors, install the bumper
⇒ “2.1 Rear bumper”, page 135 .
4. Cutting out the openings for the parking aid sensors (drill) 141
64 – Glazing
1 Glued windows
1.1 Tools
Note
The removal of the glued windows is described in the separating

device for glued windows - V.A.G 1474 A- . The corresponding
tools from the separating device for glued windows - VAS 6452-
can also be used or use the window removal set -VAS 6888- .
Special tools and workshop

equipment required
♦ Separating device for glued windows - V.A.G 1474 A- , sepa‐

rating device for glued windows - VAS 6452- or separating
device for glued windows - VAS 6888- or separating device for
glued windows - VAS 861 001- .
♦ Suction cup - V.A.G 1344-
142 Rep. gr.64 - Glazing

♦ Cutting tool - V.A.G 1351-

♦ Window removal set - V.A.G 1755-
♦ Hand pressure gun - V.A.G 1628-
♦ Cartridge heater - V.A.G 1939-
♦ Power knife - V.A.G 1561 A-
♦ Cutting knife - V.A.G 1561/2-
♦ Setting gauge - 3371-
♦ Double cartridge gun - VAS 5237-
♦ Cutting thread - 357 853 999 B-
♦ Cutting cord - 357 845 955-
1.2 Materials
Note
The part numbers of the materials are provided in the ⇒ Electronic

Catalogue of Original Parts - ETKA .
♦ Activator 7) 1
♦ Glass/paint primer 7) 1
♦ Cleaning solution 7) 1
♦ Primer applicator 7) 1
♦ Adhesive remover 7) 1
7) Observe the handling instructions in accordance with the specifications of the

manufacturer in the package insert.
8) Observe minimum hardening time.
9) According to manufacturer's instructions heat up e.g. with cartridge heater -
V.A.G 1939- .
10) Use for example the double cartridge gun - VAS 5237- for processing this
material.
11) Small cartridges 180 ml for sealing work, or if 400 ml cartridge is not adequate.
12) When using a 2K window pane component adhesive, remove the first 10 cm
of the pressed out adhesive in order to ensure the correct mixture of both com‐
ponents.
1.3 Windscreen - Summary of components
WARNING
For safety reasons, re-using a cut-out windscreen is not permis‐

sible. The windscreen must always be replaced with a new orig‐
inal part. The cut-out rear and side windows can be re-used after
a thorough inspection.
1. Glued windows 143

1 - Windscreen
❑ Remove windscreen
⇒ “1.4 Removing wind‐
screen”, page 144 .
❑ Install windscreen
⇒ “1.4.1 Installing wind‐
screen”, page 146 .
2 - PUR - glue sealing material
❑ Adhesive bead cross-
section -width b- = 6 - 8
mm, - height a - = 10 - 12
mm (including the seal‐
ing section, residual
sealant on window and
window flange).
❑ Minimum hardening
time
⇒ “1.15 Minimum hard‐
ening time”, page 156 .
3 - Body flange
4 - Gap size
❑ From the lateral window
edge up to the A pillar.
❑ Set the constant dimen‐
sion of 2.5 ± 0.5 mm with
the setting gauge -
3371- .
5 - Gap size
❑ From the top window
edge up to the roof
edge.
❑ Set the constant dimen‐
sion of 2.5 ± 0.5 mm with
the setting gauge -
3371- .
6 - Window pane adjuster
❑ Remove the window pane adjuster at the earliest 120 minutes after installing the window pane.
7 - Fitting section
❑ Is part of the windscreen.
8 - Plenum chamber cover
❑ It must only be pulled from the fitting section by hand.
❑ Remove the plenum chamber cover ⇒ “1.8 Plenum chamber cover”, page 13 .
❑ Install plenum chamber cover ⇒ “1.8.3 Installing”, page 15 .
1.4 Removing windscreen

– Remove A-pillar trim panel
⇒ “3.1 Removing and installing top trim panel of pillar A”, page
263 .
– Remove all sun visors
⇒ “2.6 Removing and installing the sun visor”, page 208 .
– Removing interior rear-view mirror
⇒ “1.2 Removing and installing the interior rear-view mirror”,
page 197 .

– The moulded headliner can now be lowered sufficiently so that

the windscreen can be cut out without damaging the moulded
headliner.
– Remove the plenum chamber cover
⇒ “1.8 Plenum chamber cover”, page 13 .
– Slide the cover foil - 1 - between the windscreen and the dash
panel.
– Pull the end of the cutting thread - 2 - through the sealing ma‐
terial into the vehicle interior using the awl.
– Secure the end of the cutting thread with clip - 3 - against pull‐
ing out.
– Insert the cutting thread - 2 - with the help of the pipe - 1 - into
the window frame.
– Lay the cutting thread around the windscreen.
– Ensure that the cutting thread is laid at the corners under the
windscreen.

– Attach the other end of the thread to the spooler.

– Position the spooler in “position l”.
– Move the spooler gradually if required and cut out the wind‐
screen.
– During the cutting procedure, press the cutting thread with a
plastic wedge against the windscreen in order to create a
clearance between the window flange and the dash panel.
1.4.1 Installing windscreen
Note
When installing the windscreen, a second mechanic is required.
Prepare new windscreen for fitting

Prepare body flange for fitting
Installation instructions
Minimum hardening time
⇒ “1.15 Minimum hardening time”, page 156 .
1.5 Rear window - Summary of components

1 - Spacer
❑ If these spacers are cut
off during window re‐
moval, new spacers
must be glued on during
re-installation ⇒ ETKA .
2 - Rear window
❑ Removing
stalling the rear win‐
dow”, page 147 .
❑ Installing
⇒ “1.7 Installing rear
window”, page 149 .
3 - Body flange
4 - PUR - glue sealing material
❑ Adhesive bead cross-
section: width - b - = 6 -
8mm height - a - = 10 -
12 mm (including the
sealing section, residual
sealant on window and
window flange).
❑ Minimum hardening
time
⇒ “1.15 Minimum hard‐
ening time”, page 156 .
5 - Sealing section
1.6 Removing and installing the rear win‐

dow
Removing damaged window
WARNING
It is essential to wear protective goggles and gloves when cut‐

ting hardened PUR adhesive sealing material and when han‐
dling the cutting cord.
Observe the electrical wiring harnesses routed under the win‐
dow when cutting the rear window.
– Protect vehicle interior from glass splinters.

– Remove high-level brake light ⇒ Electrical system ⇒ Rep. gr.
94 .
– Remove rear window wiper (if present) ⇒ Electrical System
⇒ Rep. gr. 92 .
– Disconnect the plug connections of the heated rear window
and press the contact tabs onto the window.

hesive tape.
– Remove glass pieces up to the glue sealing material.
– Cut back the adhesive sealant e.g with electrical cutting tool -
V.A.G 1561/A- to approx. 1 mm thickness.
– Suction off glass residues in the vehicle as well as in the hol‐
lows of the tailgate (release cable ducts) with a vacuum clean‐
er.
Removing undamaged window
WARNING

– Remove high-level brake light ⇒ Electrical system ⇒ Rep. gr.

94 .
– Remove rear window wiper (if present) ⇒ Electrical System
⇒ Rep. gr. 92 .
– Disconnect the plug connections of the heated rear window
and press the contact tabs onto the window.
hesive tape.
– Pull the cutting thread with the awl through the sealing material
towards the inside.
– Secure the end of the cutting thread with the pull handle
against pulling out.
– Lay the cutting thread around the rear window - 1 - and guide
the second end of the thread towards the inside.
– Attach the end of the cutting thread to the spooler.
– Slide the cover foil carefully between the rear window and the
moulded headliner.
– Position the spooler in the indicated position (l and Vl).

– Move the spooler gradually if required and cut out the wind‐
screen.
– During the cutting procedure, press the cutting thread with a
wedge against the rear window to create a clearance at the
window flange.
– Use the suction cup to remove the window from the vehicle.
Note
A second mechanic is required for removing the window.

1.7 Installing rear window
Note
When installing the rear window, a second mechanic is required.
– Prepare new window for fitting

⇒ “1.12 Preparing the new window for fitting”, page 154 .
– Prepare new windscreen for fitting
– Prepare body flange for fitting
– Place the window in the fitting location on the body flange with
the help of two suction cups.
– Installation instructions
– Minimum hardening time
⇒ “1.15 Minimum hardening time”, page 156 .
1.8 Extended rear window (Spacebook)- Summary of components
1 - Spacer
2 - Rear window

1.9 Removing and installing extended rear

window (Spacebook)
WARNING

Removing undamaged side window

– Removing top trim panel for tailgate
hesive tape.
– Connections for heatable rear window and rear window aerials
(depending on the equipment installed in the vehicle) ⇒ Elec‐
trical system; Rep. gr. 91 .
– Remove rear window wiper ⇒ Electrical system; Rep. gr. 92 .
– To cut the window, use an electrical cutting device, e.g. -V.A.G
1561/A- or a pneumatic cutting device, e.g. -VAS 5177- , cut‐
ting thread - 357 853 999 B- or cutting cord - 357 845 955- or
separating device e.g. -V.A.G 1474 A- .
– Cut back adhesive cement to a thickness of approx. 1 mm.
WARNING

– Removing top trim panel for tailgate

– Connections for heatable rear window and rear window aerials
(depending on the equipment installed in the vehicle) ⇒ Elec‐
trical system; Rep. gr. 91 .
– Remove rear window wiper (incl. wiper motor) ⇒ Electrical
system; Rep. gr. 92 .
hesive tape.

– To cut the window - 1 -, use an electrical cutting device, e.g. -

V.A.G 1561/A- or a pneumatic cutting device, e.g. -VAS
5177- , cutting thread - 357 853 999 B- or cutting cord - 357
845 955- - 2 -.
– If the spacers are cut off during window removal
⇒ Item 1 (page 149) , new spacers must be glued on during
re-installation ⇒ ETKA .
Installing side window
Note
When installing the rear window, a second mechanic is required.
Prepare flange for fitting

Preparing the window for gluing
Adhering rubber buffer onto rear window.
Gluing on
Waiting time ⇒ “1.15 Minimum hardening time”, page 156 .
Further work occurs in reverse order to removal.
1.10 Removing and installing side window

(Spacebook)


2 - Fixing bolts
3 - Seal
❑ Is part of the window.
4 - Side window
1.11 Removing and installing side window

(Spacebook)
WARNING

Removing undamaged side window

– Remove top trim panel of pillar C and D
⇒ “3.7 Removing and installing C and D pillar trim panels
(Spaceback)”, page 270 .
hesive tape.
– Remove antenna plug (depending upon equipment).

– For cutting the disc, use e.g. an electric cutting device -V.A.G
1561/A- or cutting wire - 357 853 999 B- or cutting cord - 357
845 955- .
Note
When cutting the window, pay attention at the point of the distance
clips which are vulcanized to the window.

WARNING

– Remove top trim panel of pillar C and D

⇒ “3.7 Removing and installing C and D pillar trim panels
(Spaceback)”, page 270 .
– Remove antenna plug (depending upon equipment).
hesive tape.
– To cut the window, use an electrical cutting device, e.g. -V.A.G
1561/A- or a pneumatic cutting device, e.g. -VAS 5177- or
cutting thread - 357 853 999 B- or cutting cord - 357 845 955- .
Note
When cutting the window, pay attention at the point of the distance
clips which are vulcanized to the window.

Installing side window
Prepare flange for fitting
Preparing the window for gluing
Gluing on
Waiting time ⇒ “1.15 Minimum hardening time”, page 156 .
Mount antenna plug (depending upon equipment).

1.12 Preparing the new window for fitting
1.12.1 Cut back the adhesive bead

Note
♦ Cut back the remaining glue sealing material to 1-2 mm just

prior to adhering again. While doing so, do not damage the
glass/primer and ceramic layer.
♦ The remainder of the sealing compound serves as a base for
the newly applied adhesive sealant.
WARNING
Do not prime the adhesive surface and do not treat with clean‐
ing solution. Keep the adhesive surfaces free of dirt or grease.
Exception: If the bonding is not carried out immediately after cut‐

ting back, the sealing compound must be activated with the
activator.
1.12.2 Prepare new window for fitting

All the windows are not pre-layered as a spare part.
Note
♦ The area where the adhesive bead is applied is neither pre-

layered nor primed.
♦ The sealing lip is a component part of a new windscreen.
– Clean edge of the window (where glass/paint primer will be

applied) up to a width of approx. 20 mm with cleaning solution.
– Next, wipe off the edge of the window (where glass/paint pri‐
mer will be applied) using a dry, lint-free cloth not contamina‐
ted with any substances.
WARNING
The ceramic layer on the window is no glass/paint primer! It is

absolutely essential to prime it before applying the sealing ma‐
terial! Only use glass/paint primer D 009 200 02!
– Now apply the glass/paint primer with the applicator uniformly

in one go.
♦ Minimum hardening time approx. 10 minutes.

1.13 Prepare body flange for fitting

– Cut back the sealing compound on the body flange using the
U-shape cutting knife - V.A.G 1561/3- . However do not re‐
move completely.
Note
The remainder of the sealant serves as a base for the newly ap‐
plied glue sealing material. Keep the adhesive surfaces free of
dirt or grease.
WARNING
The activator must not come into contact with paintwork, oth‐
erwise there will be paint damage.
Exception: If the bonding is not carried out immediately after cut‐

ting back, the sealing compound must be activated with the
activator - D 181 801 A1- .
♦ If the body flange was reworked or only partly replaced, clean
this area again after painting and treat it with glass/paint pri‐
mer.
Note
Under some circumstances, it is possible that a laser welding

seam is not present in the area of the adhesive bead. Then the
exposed welding seam must be sealed before gluing the window
with the window pane adhesive.
– If the laser welding seam - 3 - at the metal flange - 4 - is not

covered with an adhesive bead - 1 -, coat the laser welding
seam - 3 - with glass/paint primer - D 009 200 02- - 3 -. After
airing the glass / paint primer, fill the welded seam with window
adhesive - 1 -.
1.14 Installation instructions for all panes

– Apply the adhesive cement all around at a right angle to the
window.

WARNING
The window must be inserted within 10 minutes as otherwise

the adhesion of the window adhesive may be poor.
Do not apply the adhesive bead too thick and do not press the
windows too hard on the body flange. Oozed adhesive can be
seen in the area of the joints because the windows do no longer
have any sealing lips.
♦ Insert the window into the body flange, for example using the
suction cup - V.A.G 1344- , take the mean and press in up to
the spacer web.
♦ Re-stick any existing stickers (for example for airbag).
1.15 Minimum hardening time
WARNING
Comply with special requirements when replacing glued win‐

dows. Among these are for example, that a newly glued wind‐
screen must fulfil the operational safety in the event of an
accident after a prescribed minimum hardening time.
For the 2K adhesive the minimum cure time for all slices is 3 hours
(or as recommended by the manufacturer on package leaflet).
With the minimum hardening time is meant the time from the mo‐
ment the window is glued until the vehicle is used. During this
time, the vehicle must stand on a flat surface at room temperature
(at least 15 °C).
WARNING
The vehicle is only safe for driving after the minimum hardening
time has expired.
1.16 Window repairs
Note
♦ In case of damage to the windscreen, it must be clarified

whether the glass can be repaired before replacing the wind‐
screen.
♦ Damaged windscreens can be repaired using the window re‐
pair set - VAS 6092- .
♦ The damage must not exceed a certain size and location.
♦ An instruction manual is enclosed with each pane repair kit.

♦ Pane repair kit - VAS 6092- or -VAS 6093- .
1.17 Cleaning necessary due to soiling

through glue sealing material
– We recommend using glue remover for cleaning. Observe
safety regulations while working.
WARNING
When cleaning the vehicle interior, the window which was just
inserted must not be pressed towards the outside.
– Clean the paint surfaces with a dry cloth. Remove the glue
residue with glue remover.
– Clean plastic fillings: leave glue sealing material to harden
(approx. 1 hour) and then pull off.

66 – Exterior equipment
1 Wheelhouse liner
1.1 Front wheelhouse liner
1.1.1 Removing
– Remove wheel ⇒ Chassis; Rep. gr. 44 ; tightening torques

for the wheel bolts .
– Pull out wheelhouse liner -1-.
158 Rep. gr.66 - Exterior equipment

1.1.2 Installing
Note
Check the expanding nuts - 2 - for damage, replace them if necessary.
– Insert wheelhouse liner - 1 - in the wing.

– Install screws -2-. Tightening torque - 2 Nm.
1. Wheelhouse liner 159

1.2 Rear wheelhouse liner
1.2.1 Removing
– Remove wheel ⇒ Chassis; Rep. gr. 44 ; tightening torques

for the wheel bolts .
– Pull out rear wheelhouse liner - 1 -.

1.2.2 Installing
DANGER!
Check the expanding nuts - 2 and 3 - for damage, replace them

if necessary.
The expanding nuts seal the interior from exhaust gases. In
case of damage, they must absolutely be replaced.
– Insert the rear wheelhouse liner - 1 - into the wheelhouse with‐

out any kinks.
– Install wheel ⇒ Chassis; Rep. gr. 44 ; tightening torques for
wheel bolts .
1. Wheelhouse liner 161

2 Exterior mirrors
1 - Screw
❑ 1 Nm.
2 - Mirror tilting mechanism
– Remove mirror glass
installing mirror glass”,
page 163 .
3 - Mirror housing
installing the mirror
housing”, page 164 .
4 - Screw
5 - Bearing part of mirror
6 - Mirror holder with link
7 - Mirror glass
installing mirror glass”,
page 163 .
8 - Electrical cable with plug
connection (depending on ver‐
sion)
9 - Mirror frame
10 - Mirror inner lining
11 - Damping

2.1.1 Removing and installing mirror glass
WARNING
Wear protective gloves and protective goggles when working!
Removing
– Protect the edges of the housing for damage, e.g. cover with
textile adhesive tape.
– Swivel the mirror glass - 1 - in the maximum position.
– Press off the mirror glass -1- from the holder -2- and the hous‐
ing -arrow a- for example using a wide plastic wedge.
Installing
– Press the mirror glass in the centre onto the holder in the
housing.
The mirror glass clicks audibly into place.
• Subsequently perform a functional test.
2. Exterior mirrors 163

2.1.2 Removing and installing the mirror housing
Removing
– Remove mirror glass
⇒ “2.1.1 Removing and installing mirror glass”, page 163 .
– Release locking tabs -arrows-.
– Slide out mirror housing from the bearing part of the mirror
towards the rear.
Installing
– Press mirror housing into the tabs until it audibly clicks into
place.

2.1.3 Removing and installing frame
Removing
– Remove mirror housing
⇒ “2.1.2 Removing and installing the mirror housing”,
page 164 .
– Release the tabs on the reverse side.
– Release the tabs on the front side.
– Remove frame from bearing part of mirror.
Installing

2.1.4 Removing and installing exterior mirror

(electric operating lever)
2.1.5 Removing

– Disconnect the plug connection - 2 - of the electrical line - 3 -
for the exterior mirror - 1 -.

– Swivel out the exterior rear-view mirror - 1 - in the lower area

from the door and pull out of the window run - 2 - -arrow-.
– Guide the cable - 3 - through the opening in the door.

2.1.6 Installing

– Check correct seating of the insulation.
– Guide the line - 3 - through the opening (depending on the
vehicle equipment).
– Insert the exterior mirror - 1 - into the provided opening in the
door.
– Mount plug -2-.
door trim panel.

3 Strips and trims
3.1 Summary of components - trim strips and covers

Monte Carlo front spoiler
1 - Bumpers
2 - Engine trim panel
3 - Monte Carlo front spoiler
4 - Screw
Nm.
Monte Carlo - Spaceback front spoiler
3. Strips and trims 169

1 - Bumpers
2 - Engine trim panel
3 - Monte Carlo front spoiler
Monte Carlo rear spoiler

1 - Rear bumper
2 - Monte Carlo rear spoiler
Monte Carlo - Spaceback rear spoiler

1 - Rear bumper
2 - Monte Carlo rear spoiler
3.2 Removing and installing the cover
Note
♦ The ambient temperature as well as the temperature of the

parts must be at least 18 °C, maximum 30 °C.
♦ After glueing the tuning parts, the vehicle must remain in a
warm room for at least 3 hours.
♦ Before glueing, all of the adhesive surfaces must be de‐
greased with good quality - the quality of the glued joint de‐
pends upon this!
Adhesive mate‐ Part number Purpose, application range Denomination, manufacturer,

rials comment
PUR - adhesive D 172 090 A2 Glue tuning parts to the body. Caution: Comply with the
manufacturer's handling in‐
structions. Filling: 310 ml
Glass/paint pri‐ D 822 150 A1 Prepare the plastic surfaces before Filling: 10 ml
mer for plastic gluing to improve adhesion of the plas‐
parts tic


rials comment
Glass/paint pri‐ D 009 200 02 Prepare the plastic surfaces before Filling: 10 ml
mer for plastic gluing.
parts
Cleaning solu‐ D 195 850 A1 For cleaning all surfaces to which
tion glass/paint primer and glue is applied.
Applicator D 009 500 25 Apply glass/paint primer and activator.
Installing the spoiler

– Clean and degrease the adhesive surfaces with cleaning sol‐
ution - D 195 850 A1 -.
– Apply glass/paint primer - D 822 150 A1 - to adhesive area on
the plastic part -1 and 3-.
– After drying, apply glass/paint primer - D 009 200 02 - to the
adhesive area on plastic part -1 and 3-.
– Apply adhesive cement -5- - D 172 090 A2.
– Press on the spoiler at a specific point.
– Install screws -4- (1.5 Nm).
– Secure spoiler against moving and ungluing e.g. with adhesive
tape.

– Only apply adhesive cement to the area -1- of the spoiler -2-.

Removing
– The spoiler cannot be removed without being destroyed.
Installing the rear spoiler - Spaceback
tape.


Removing
Install the rear spoiler
– Screw in screw - 4 - (1.5 Nm).
tape.


Removing
3.3 Removing and installing door sill panel

⇒ “3.3.1 Removing and installing door sill panel ”, page 179
⇒ “3.3.2 Removing and installing door sill panels”, page 182
3.3.1 Removing and installing door sill panel

Removing
– Release screws -1- and -3-.
– Press the sill panel in direction of arrow -A-.

– Push out the sill panel in the direction of arrow -B-.

Installing
– Clip the front - 2 - and rear - 3 - adapters into the openings (if
removed).
– Dimensions for installing the special screws.
Table of dimensions
Dimension -a - = 867.5 ± 2 mm
Dimension -b - = 758.3 ± 1 mm

Dimension -c - = 560.3 ± 1 mm
Dimension -d - = 373.5 ± 1 mm
Dimension -e - = 186.8 ± 1 mm
Dimension -f - = 746.9 ± 1 mm
Dimension -g - = 560.2 ± 1 mm
Dimension -h - = 373.5 ± 1 mm
Dimension -i - = 186.8 ± 1 mm
Dimension -j - = 62.4 mm
Dimension -k - = 60.7 mm
Dimension -l - = 58.8 mm
Dimension -m - = 56.9 mm
Dimension -n - = 54.9 mm
Dimension -o - = 52.7 mm
Dimension -p - = 50.5 mm
Dimension -r - = 48.2 mm
– Do not predrill holes for screws -2- (1.2 Nm), they are self-
tapping.
Note
A second mechanic is required to push out the sill panel -2-.
– Push out the sill panel -3- in direction of arrow -A-.

– Press the sill panel -3- onto the side rail and slide along it in
direction of arrow -B-.

– Install screws -3- (2.5 Nm) and -1- (1.5 Nm).
3.3.2 Removing and installing door sill panels
Note
♦ The ambient temperature as well as the temperature of the

parts must be at least 18 °C, maximum 30 °C.
♦ After glueing the tuning parts, the vehicle must remain in a
warm room for at least 24 hours.
♦ Before glueing, all of the adhesive surfaces must be de‐
greased with good quality - the quality of the glued joint de‐
pends upon this!
♦ Ensure thorough ventilation of the working area.
♦ The adhesive surface of attachments must not be painted!
♦ Attachments can only be glued to the vehicle after thorough
curing of the body paint.

rials comment
Glue sealing Betalink K2 Glue tuning parts to the body. Observe the manufacturer
material DOW’s instructions.
Activator Betaprime 5600-1 Prepare the surfaces before gluing to DOW
improve adhesion.
Cleaning solu‐ Terostat 8550 For cleaning all surfaces to which Henkel
tion glass/paint primer and glue is applied.
Applicator D 009 500 25 For applying the activator.

Mount side rail attachments

– Insert the adapters into the holes after removing blind plugs
- 2 and 3 -.
– Wash the surfaces with a mild detergent solution and rinse
with clean water.
– Clean surface with Terostat 8550 cleaner and degrease, then
allow to ventilate (10 minutes).
– Check the position of the end piece and check whether the
rear bore on the end piece is aligned with the bore of the plastic
wheel housing rear end, and that the other four holes are
aligned with the adapter holes.
– Carefully ark the designated area of the endpiece with sand‐
paper (grain size 80).
– Clean surface with Terostat 8550 cleaner and degrease, then
Note
The adhesive surface must be completely free of grease, lacquer

residue and primer.
– Apply activator Betaprime 5600-1 to the cleaned surfaces and

– Spray the nozzle of the adhesive cement so that the inner di‐
ameter is approx. 8 mm.
– Apply adhesive to all surfaces that come into contact with the
side rail.
– With a second mechanic, place the lower side of the end piece
onto the adapter mounting holes.
– Do not press the upper edge yet.

– Attach the middle screws to the adapter (do not tighten), press
the attachment on the side rail, install the screw on the rear of
the extension and then install the screws on the outside of the
adapter.
– Do not displace the side rail end piece since the adhesive can
flow over the edges of the end piece.
– Tighten the screws to 2.5 Nm (adapter connections) and the
rear screw (rear wheel hub connection) to 1.5 Nm.

– Attach the attachment with tape approximately as shown.

– Remove the adhesive tapes from the endpiece after one hour.
– Remove queezed out parts of the adhesive cement, e.g with
a plastic spatula and clean with a cleaner.
Note
Do not drive into the carwash within 24 hours of gluing on the

attachments.
Remove side rail attachments
Note
♦ The side rail attachments cannot be removed without damage.

♦ After removaing the side rail, check the lacquer on the side
rail.
– Cover the painted surfaces in the attachment area with textile

adhesive tape.
– Remove all screws for picking up the end piece.
– Heat the glued connection points gradually with hot air blow‐
ers.
– Cut off the attachment with accessible workshop equipment
(cut through sealing material).
– Remove the old adhesive using a standard workshop tool and
an adhesive remover (if a new end piece is glued to the side
rail).
3.4 B-pillar trim panel

1 - B-pillar trim panel

2 - Fixing pins
❑ Part of the trim.
3 - Screw
Nm.
4 - Foam strip
❑ Self-adhesive.
5 - Dowel
6 - Grommet

3.4.2 Removing
Note
The trim cannot be removed without being destroyed.

– Lever the fixing pins -2- out of the grommets -6- e.g. using a
wedge.
– The fixing pins will probably tear and remain in the grommets
-6-.
– Remove the trim -1- from the B pillar.
– Remove residues of torn pins and glue residues from the self-
adhesive strips - 4 -.
Installing

3.5 Cover strip of wing
3.5.1 Installation instructions for cover strip of

wing
Note
♦ Use only the glue remover - D 002 000 10- .

♦ Make sure that the adhesive surfaces are free from dust and
grease.
♦ The cover trip must be glued on immediately after cleaning.
♦ Remove protective foil from its wrapping until just before as‐
sembly.
♦ The processing temperature is about 21 ℃.
3.5.2 Removing and installing cover strip of wing

Removing
– Detach the cover strip -1- from the wing -2-.
Installing
– Remove glue residues -3-.
– Slide the cover strip onto the wing -2-.
– Detach the protective foil - 4 -.
– Forcefully press the cover strip -1- onto the adhesive surface
-3- at the wing -2-.

4 Rear spoiler
4.1 Rear spoiler - Rapid
– Rear spoiler -3-.

– Adhesive tape -1-.
– Glue sealing material -2-.
Removing the rear spoiler
– Cover the painted surfaces along the spoiler with textile ad‐
hesive tape.
– Cut off spoiler from the tailgate (cut through glue sealing ma‐
terial) and cut off double-sided adhesive tape, e.g. with cutting
cord -357 853 999 B - .
– Remove the spoiler.
4. Rear spoiler 189

Install the rear spoiler
Note
The ambient temperature must be above 18°C during the gluing procedure of the spoiler!
– Thoroughly clean the adhesive surfaces e.g. with cleaning

solution D 009 401 04.
– Apply glue sealing material D 172 090 A2 into the guiding
groove (Pos. 2) in the spoiler.
– Stick on the spoiler within 15 minutes after applying the glue
sealing material!
– Partially unglue the protective foil from the adhesive tape on
the edges.
– Position the spoiler evenly onto the tailgate.
– Maintain an equal gap of 2 mm from the side tailgate edge.
– Remove the protective foil from the adhesive tape.
– Press the spoiler evenly onto the tailgate.
– Secure spoiler against moving with adhesive tape.
Note
♦ The adhesive cement must dry for 2 hours. Do not drive the vehicle in this time.
♦ Do not drive into the carwash within 24 hours of gluing on the spoiler.
4.2 Rear spoiler - Spaceback

1. Tailgate
2. Spoiler
3. Glue sealing material
4. Double-sided adhesive tape
Removing
Note
Removal is not possible without paint damage to luggage com‐

partment and spoiler.
– Cover the painted surfaces along the spoiler with textile ad‐
hesive tape.
– Cut off spoiler from the tailgate with available workshop means
(cut through glue sealing material).
– Remove the spoiler.
4. Rear spoiler 191

Installing
Note
The ambient temperature must be above 18°C during the gluing

procedure of the spoiler!
– Thoroughly clean the adhesive surfaces e.g. with cleaning

solution D 009 401 04.
– Apply glass/paint primer D 181 650 A1 to the adhesive surfa‐
ces of the spoiler and let them dry off.
– Apply glue sealing material D 172 090 A2 into the guiding
groove in the spoiler.
– Stick on the spoiler within 15 minutes after applying the glue
sealing material!
– Partially unglue the protective foil from the adhesive tape on
the edges.
– Position the spoiler evenly onto the tailgate.
– Maintain an even gap.
– Remove the protective foil from the adhesive tape.
– Press the spoiler evenly onto the tailgate.
– Secure spoiler against moving with adhesive tape.
Note
♦ The glue sealing material must dry for at least 2 hours. Do not
drive the vehicle in this time.
♦ Do not drive through the carwash within 24 hours of gluing on
the spoiler.

5 Letterings
5.1 Installation instructions

♦ Warm up the letterings with a hot-air blower before removing.
♦ If a lettering is removed or installed, only use the glue remover
- D 002 000 10- to remove the glue residues.
♦ If necessary, remove adhesive residues from the adhesive
tape.
♦ Make sure that the adhesive surfaces are free from dust and
grease.
♦ The letterings must be glued on immediately after cleaning.
♦ Remove protective foil from its wrapping until just before as‐
sembly.
♦ The processing temperature is about 21 ℃.
♦ The letterings cannot be removed without being damaged.
5.2 Removing and installing the emblem on the tailgate
5. Letterings 193
Removing
– Warm up the emblem - 1 - with a hot-air blower before remov‐
ing.
– Remove the logo from the tailgate - 2 -.
Installing
– Pay attention to installation instructions
⇒ “5.1 Installation instructions”, page 193 .
– Detach the protective foil - 3 -.
– Place the emblem - 1 - with the centering pins into the em‐
bossed area of the tailgate - 2 -.
– Forcefully press on the emblem - 1 - .
5.3 Dimensions of letterings on the tailgate - Spaceback
1 - Škoda lettering
❑ a = 28.1 ± 0.25 mm
❑ b = 23.2 ± 0.25 mm
❑ c = 23.4 ± 0.25 mm
2 - Tailgate
3 - Rapid lettering
❑ d = 23.5 ± 0.25 mm
❑ e = 23.4 ± 0.25 mm
❑ f = 27.8 ± 0.25 mm

5.4 Dimensions of letterings on the tailgate - Rapid
1 - Škoda lettering
❑ a = 28.6 ± 0.25 mm
❑ b = 23.4 ± 0.25 mm
❑ c = 23.4 ± 0.25 mm
2 - Tailgate
3 - Rapid lettering
❑ d = 23.2 ± 0.25 mm
❑ e = 23.2 ± 0.25 mm
❑ f = 28 ± 0.25 mm
5. Letterings 195
5.5 Trailer coupling

⇒ “5.5.1 Summary of components - Trailer coupling”, page 196 .
5.5.1 Summary of components - Trailer coupling
1 - Trailer coupling frame

Removing

er
rear bumper”,
page 136 .
– Remove power socket

-6-.
– Release screws
⇒ Item 8 (page 196) .
– Pull out trailer hitch

frame backwards.
Installing

in reverse order.
2 - Protective cap
3 - Trailer arm
– Carry out the removal

and installation accord‐
ing to the instructions of
the manufacturer of the
trailer coupling.
4 - Adhesive pad
♦ Insert into the hole after re‐
moving the trailer arms.
5 - Screw
❑ 2.5 Nm.
6 - Power socket
Removing
– Remove screws (Pos. 5).
7 - Wiring loom
8 - Screw
❑ 55 Nm + 90° .
❑ 55 Nm + 180° - Spaceback.

68 – Interior equipment
1 Interior rear-view mirror
1.1 Tools
♦ Disassembly wedge - 3409-
1.2 Removing and installing the interior

rear-view mirror
1.2.1 Removing
– Turn interior mirror -2- by 90° in -direction of arrow- and re‐
move from the retaining plate -1-.
1. Interior rear-view mirror 197

Installing
198 Rep. gr.68 - Interior equipment

1.2.2 Removing interior rear-view mirror with

rain and light detector sensor
Removing
– Switch off the ignition and all electrical components.
– Unclip cable cover -2-.
– Unclip cover -4- from the retaining plate.
– Turn mirror -3- 20° anticlockwise.
– Remove mirror -3- from retaining plate -5-.
– Disconnect connector -1- from plug connection.
Installing
– Insert connector -1- into plug connection.
– Turn mirror -3- 20° anticlockwise and position to retaining plate
-5-.
– Ensure the mirror is seated parallel and turn clockwise until it
locks into place.
– Install cap -4-.
– Install cable cover -2-.

Removing retaining plate for interior mirror with sensor for rain
and light detection
Note
The retaining plate for interior mirror with sensor for rain and light
detection cannot be glued on under workshop conditions. Is part
of the windscreen.
1.3 Glueing the retaining plate for the interi‐

or rear-view mirror
1.3.1 Materials
♦ Glass metal adhesive kit - D 000 703 A1-
1. Interior rear-view mirror 199

1.3.2 Installing
Tools
1 - Glass scraper (commercially available)
2 - Blade (commercially available)
– Remove retaining plate from mirror pedestal.
– Remove PUR adhesive kit from the retaining plate with a wire
brush.
– Grind down the three distance knobs on the adherent. Place
abrasive paper (grain 360/400) on a flat surface.
– Sanded surfaces must be clean and free from grease.
– Using the glass scraper, scrape the old PUR adhesive and
glass/paint primer residues down to the ceramic layer on the
windscreen.
– Clean the bonding surface with glue remover - D 002 000 10-
or cleaning solution - D 009 401 04- .
WARNING
Do not damage the ceramic layer. Scratches remain visible.
– Cut a piece of nylon net fabric to the exact size of the retaining
plate.
Note
Wear hand protection (rubber gloves).
– Apply adhesive evenly on the retaining plate.

– Fit a piece of nylon net fabric onto the retaining plate.
– Continue applying adhesive by dabbing on the nylon net fab‐
ric.
Once the nylon net fabric is placed on the adhesive, you only have
30 seconds to press it onto the windscreen.
– Press the retaining plate steadily onto the windscreen for 15
seconds (do not force).
– Remove excess adhesive with a cloth.
Note
Install the interior rear-view mirror after 15 minutes.

2 Covers, storage areas and trim pan‐

els
2.1 Tools
♦ Disassembly wedge - 3409-
2.2 Centre console
2. Covers, storage areas and trim panels 201

1 - Centre console
2 - Armrest

2.2.2 Removing and installing centre console
1 - Drink holder and storage

area
❑ Clipped onto centre
console.
2 - Screw
Nm.
3 - Cap of handbrake
❑ Clipped onto centre
console.
4 - Centre console
Removing
– Switch off the ignition

and all electrical compo‐
nents.
– Unclip the trim panel for

the shift lever ⇒ Gear‐
box; Rep. gr. 34 .
– Remove armrest (de‐

pending upon vehicle
equipment)
stalling the armrest”,
page 206 .
– Remove cap (Pos. 6).
– Remove screws (Pos.

2).
– Remove=ing handle for

handbrake lever ⇒
braking systems; Rep.
gr. 46 ; Handbrake;
summary of handbrake components .
– Apply handbrake fully.
– Unclip the cap on the handbrake (Pos. 3).
– Press console approx. 30 mm in direction of engine - arrow A - and unclip from the holders for the dash
panel.
– Swivel out console in -direction of arrow B-.
– Disconnect the plug connection of the cigarette lighter (power socket) ⇒ Electrical System - General
notes; Rep. gr. 96 .
– Remove the trim panel from the vehicle.
Installing
5 - Storage tray
❑ Clipped onto centre console.

6 - Cap
❑ The fixing screw for the centre console is located under the cap.
2.2.3 Replacing the central console

– When replacing the central console you will also need to cut
out the openings for the button for tyre pressure inspection and
AUX IN socket (depending on the equipment to be installed in
the vehicle). The process of cutting out the console is done
with standard workshop tools. A pattern is not required. The
opening contours are marked as standard on the central con‐
sole from the reverse side - arrows - .
2.2.4 Removing and installing the bracket of the centre console
– Removing the centre console

⇒ “2.2.2 Removing and installing centre console”, page 203 .
– Release nuts (Pos. 1).
– Remove the bracket (Pos. 2) from the vehicle.
Installing

2.3 Summary of components – armrest
1 - Armrest
2 - Sustainer
3 - Screw
Nm.
4 - Cover for left armrest pivot
5 - Cover for right armrest pivot
2.4 Removing and installing the sustainer

(vehicles with armrest)
Removing
– Remove armrest
⇒ “2.5 Removing and installing the armrest”, page 206 .
– Release screws -arrows- (4 Nm).

– Take off sustainer -1-.

Installing
2.5 Removing and installing the armrest

Removing side covers of the armrest
– Pivot armrest to maximum position of 110°.
– Insert plastic tape in direction of arrow -A- into the gap between
armrest and cover.
– Remove (unclip) right cover (Pos. 1) in direction of arrow -B-.
– The left cover (Pos. 2) is removed in the same way.

Removing and installing front armrest

Removing
– Unclip covers for armrest pivot -4 and 5-.
– Remove screw -3- (5 Nm) and slide out the armrest -1- back
from the sustainer -2-.
Installing
2.6 Removing and installing the sun visor

Summary of components - sun visor

1 - Mounting bracket for right

sun visor
Removing
– Unclip sun visor (Pos. 3)

from mounting bracket.
– Push out the cap (Pos.

2) thereby unlocking the
expansion clips of the
mounting bracket.
– Swivel the mounting

bracket out of the roof
reinforcement.
Installing

in reverse order.
2 - Disassemble cap for mount‐

ing bracket for sun visor
3 - Sun visor
4 - Securing clip for mounting
bracket for sun visor left
5 - Caps for mounting bracket
for sun visor left
Remove left holder

– Unclip caps (Pos. 5).
– Unlock the securing clamps for example by using a pair of pli‐
ers - VAS 6427- (Pos. 4). The clamps are turned by 90°.
– Push the holder out of the roof reinforcement and remove to‐
gether with the visor.
Installing
– Clip the holder into the opening of the roof reinforcement.
– Make sure that the clamps are properly secured.
– Clip in caps (Pos. 5).
Note
Before the installation, check all the fixing elements for damage,
if necessary replace.

3 Recessed handles
3.1 Removing and installing the recessed

handles of the roof
Removing
– Fold down the recessed handle - 1 - and swivel out the cap
- 2 -.
– Unlock the clips - 3 - using e.g. the release tool -T10517- or -
T10518- or -T10518A- and detach the recessed handle by
pulling from the supports.- Arrows- .
Installing
– Press recessed handle - 1 - with the supports into the bores
in the bracket for the recessed handle.
– Press in the spreader clips - 3 - until they click audibly into
place.
– Press in the cover caps - 2 -.

Note
♦ Ensure that the spreader clips -3- are fully pressed in.
♦ The spreader clips -3- spread the clips of the recessed handle
-arrows- apart when pressing in.
3. Recessed handles 211

69 – Passenger protection
1 Seat belts
1.1 Removing and installing the front seat

belts
Removing
WARNING
♦ Observe the general safety instructions for working on air‐

bag, belt tensioner and battery separation units (pyrotech‐
nical components)
⇒ “3.3 Observe the general safety instructions for working
on airbag, belt tensioner and battery separation units (py‐
rotechnical components)”, page 225 .
♦ Observe the special instructions for the belt tensioner
⇒ “2.2 Special instructions for the belt tensioner”,
page 223 .
– Disconnect the vehicle battery ⇒ Electrical System; Rep. gr.

27 ; disconnect and connect the battery .
– Remove the trim panels of the B pillar
⇒ “3.4 Removing and installing top B-pillar trim panel”,
page 266 .
– Unclip the door sill panel towards the top out of the front side
rail.
– Unclip the door sill panel until the screw of the automatic belt
retractor can be reached.
– Unscrew the screw -1- (40 Nm) and release the belt deflection
fitting -2- from the seat belt height adjustment.
– Pull the seat belt deflection -1- out of the tab -2-.
– Guide the seat belt -3- out of the seat belt deflection -1-.
WARNING
When installing, the seat belt deflection -1- must lock audibly
into the tab -2-!
212 Rep. gr.69 - Passenger protection

WARNING
When electrostatic discharges occur, there is a risk of the belt

tensioners being activated unintentionally. Therefore, the me‐
chanic must discharge himself electrostatically before sepa‐
rating the ignition and earth lead. This occurs, for example, by
briefly touching the body or the door closing mechanism.
– Disconnect the plug connection from the automatic belt re‐

tractor.
– Release the screw (40 Nm) and remove the automatic belt
retractor -2- from the B pillar.
1. Seat belts 213

– Unscrew screw -1- (40 Nm) and loosen the belt end fitting
-2- from the body.
Installing
– Connect the vehicle battery ⇒ Electrical System; Rep. gr. 27 ;
disconnect and connect the battery .

belt height adjuster
Removing
– Slacken the upper trim panel of the B pillars from the supports
page 266 .
– Unscrew the screw -1- (40 Nm) and release the belt deflection
fitting -2- from the seat belt height adjustment.
– Screw out screw -1- (20 Nm) and remove the seat belt height
adjuster -2- from the supports in the support panel.
Installing

belt buckle
Removing
Note
On vehicles with automatic seatbelt detection system, the wiring

harness must be separated additionally at the connector station
and it must be released at the seat rack.
– Remove front seat

⇒ “1.1 Removing and installing front seat”, page 286 .

– Remove screw -2- (40 Nm).

– Remove seat belt buckle -1-.
Note
♦ The screw -2- is microencapsulated and must be replaced

each time it has been released.
♦ Before installing the new screw, the thread of the correspond‐
ing nut must be cleaned.
Installing

belt buckle
Removing
– Remove the plug -1- from the connector station below the seat.
– Unclip the wiring loom attachments -arrows- from the seat
rack.
Note
♦ The screw is microencapsulated and must be replaced each time it has been released.
♦ Before installing the new screw, the thread of the corresponding nut must be cleaned.
1. Seat belts 215

Note
♦ The screw -2- is microencapsulated and must be replaced

each time it has been released.
♦ Before installing the new screw, the thread of the correspond‐
ing nut must be cleaned.
Installing
1.5 Removing and installing the outer rear

seat belts
Removing
– Remove the seat bench
⇒ “2.1 Removing and installing the rear seat bench”,
page 295 .
– Remove the backrest depending on the vehicle equipment
⇒ “3 Removing and installing backrests”, page 298 .

– Remove top part of side luggage compartment trim panel

⇒ “5.2 Removing and installing top part of side luggage com‐
partment trim panel”, page 278 .
– Remove the end fitting - 2 - from the mounting boss - 3 -.

– Remove the automatic belt retractor -2- from the top part of
the rear panel.
1. Seat belts 217

Installing
1.6 Removing and installing the rear middle

seat belt
Removing
page 295 .
– Remove the belt buckle with the rear middle seat belt -1- from
the mounting boss -2-.
– Removing backrest
– Remove cover from backrest
⇒ “2.3 Removing and installing entire cover and backrest up‐
holstery”, page 308 .
– Release nut and remove seat belt.
Installing
1.7 Removing and installing the rear seat

belt buckle with lap belt
Removing
page 295 .

– Remove the belt buckle with the lap belt -3- from the mounting
boss -2-.
Installing
1.8 Removing and installing the rear double

belt buckle
Removing
page 295 .
– Remove the double belt buckle -2- from the mounting boss
-3-.
Installing
1. Seat belts 219

2 Inspect seat belts
WARNING
The seat belt system must be inspected systematically after

every accident! If one of the inspection points reveals any
damage inform the customer that the seat belts must be re‐
placed.
Test sequence
♦ Check seat belt.
♦ Check automatic belt retractor - locking effect.
♦ Seat belt buckle - visual inspection.
♦ Seat belt buckle - functional check.
♦ Check deflection fittings and buckle latch.
♦ Check fixing parts and fixing points.
2.1 Test sequence
2.1.1 Checking the seat belt

– Completely unreel the seat belt from the automatic belt retrac‐
tor or from the lap belt adjusting strip.
– Check the seat belt for dirt, if necessary wash it with mild soapy
water ⇒ Owner's manual .

• If damage is detected (case 1 and 2) on a vehicle which has

been involved in an accident (as shown below) - replace the
seat belt together with the belt buckle.
• If damage is detected on a vehicle which has not been involved
in an accident, as shown under point 1, 2, 3 and/or 4, it is only
necessary to exchange the damaged seat belt.
• 1) - Seat belt cut, torn or chafed.
• 2) - Torn fraying on the edge of the belt.
• 3) - Cigarette burns.
• 4) - Belt edge deformed or warped.
2.1.2 Check automatic belt retractor - locking

effect
The automatic belt retractor has 2 locking functions.
♦ The first locking function is activated when the belt is drawn
rapidly out of the automatic belt retractor (belt withdrawal ac‐
celeration).
Checking
– Draw the seat belt out of the automatic belt retractor with a
sudden sharp pull.
• No locking effect - replace seat belt together with buckle.
• First check whether the belt feeds out and retracts smoothly,
and whether the position of the inertia reel has changed.
• The second locking function is activated by a change in the
vehicle's motion (vehicle-dependent locking function). Thus,
the vehicle must be moved on a level surface.
Checking
– Put on seat belt.
– Accelerate to 20 km/h and perform a full brake with the brake
pedal.
• If the locking mechanism does not lock the belt when the
brakes are applied, replace the seat belt together with the
buckle.
WARNING
For safety reasons, carry out this test on a section of road with
no traffic so as not to endanger other road users.
2. Inspect seat belts 221

2.1.3 Seat belt buckle - visual inspection

– Check belt buckle for fractures and flaking.
• In case of damage, the seat belt and the belt buckle must be
replaced.
2.1.4 Seat belt buckle - functional check

Checking seat belt buckle:
– Insert buckle latch in the belt buckle until there is an audible
click. Check whether the locking mechanism engages, by tug‐
ging forcefully on the seat belt.
• If the buckle latch fails to lock into the buckle even once out of
at least five tests, replace the seat belt together with the buck‐
le.
Check buckle release:
– Release seat belt by pressing the seat belt buckle button.
– If the belt is loose, the latch must eject independently from the
belt buckle.
• Test at least 5 times. If the buckle latch fails to eject even once,
replace the seat belt together with the buckle.
WARNING
Never use lubricants to eliminate noises or to smoothen the

operation of the buttons on seat buckles.
2.1.5 Checking deflection fitting and buckle

latch
When the belt system is burdened (seat belt attached in an acci‐
dent) plastic-coated fittings will display fine parallel score marks.
(Normal wear and tear due to frequent use is recognisable by
smooth, even wear, without scoring.)
– Check the plastic for deformation, flakings and crackings.
• In the event of scoring and/or damage replace seat belt to‐
gether with buckle.
2.1.6 Checking fixings and fixing points

♦ Buckle tongue deformed (stretched).
♦ Fixing points (seat, pillar, underfloor) warped, or thread dam‐
aged.
• If the parts are damaged replace seat belt together with buck‐
le.
• Replace fixing points.
Note
If damage has occurred that is not due to an accident, but is the

result, for example, of normal wear and tear, it is only necessary
to replace the damaged part.

2.2 Special instructions for the belt tension‐

er
WARNING
♦ The open end of a belt tensioner must never be pointed

towards people.
♦ Handle the seat belt tensioner units with great care when
removing and installing. A high risk and injury potential
exists through rough improper handling of seat belt ten‐
sioner units.
♦ When connecting the seat belt tensioner units, all me‐
chanical parts including the parts of the three point seat
belt, must be correctly secured. If it is not possible to con‐
nect the seat belt tensioner unit because there is not
enough space, the seal belt must be fully rolled up before
connecting. In this case, there is no increased safety risk
if further safety measures are observed and respected.
These include mainly disconnecting the battery and the
electrostatic discharge of the mechanic before connecting
the seat belt tensioner unit.
♦ Depending on the accident, it may be possible that the belt
tensioner was ignited, the belt force limiter, however, was
NOT ignited. These components are handled in the same
way as non-ignited components!
2.3 Storage, transport and disposal of air‐

bag, belt tensioner and battery separa‐
tion units (pyrotechnical components)
WARNING
♦ The storage is subject to the respective national legisla‐

tion.
♦ The transport is subject to national and international leg‐
islation, in which packaging, marking, labeling, and ac‐
companying documents are regulated in detail.
♦ Non-ignited pyrotechnical components must be discarded
in the original packaging in compliance with the applicable
disposal procedure according to the national legislation!
In case you have any questions, please contact your im‐
porter.
♦ Only fully ignited pyrotechnical components may be dis‐
posed of as industrial waste.
2. Inspect seat belts 223

3 Airbag
3.1 Tools
♦ Vehicle diagnosis, measurement and information system
3.2 Airbag system - Overview
1 - Pressure sensor for side

impact, front passenger's side
2 - Side airbag unit front pas‐
senger's side
installing airbag unit on
the passenger side”,
page 235 .
3 - Head airbag
⇒ “3.17 Head airbag”,
page 239 .
4 - Acceleration sensor for side
impact, front passenger's side
5 - Side airbag unit driver's side
installing side airbag”,
page 237 .
6 - Head airbag driver's side
⇒ “3.17.1 Summary of
components - head air‐
bag”, page 239 .
7 - Acceleration sensor for side
impact, driver's side
8 - Pressure sensor for side
impact, driver's side
9 - Front airbag driver's side
installing driver airbag
unit”, page 233 .
10 - Control unit for the airbag system
❑ Removing and installing ⇒ “3.7 Removing and installing the airbag control unit ”, page 228 .
11 - Key-operated switch for deactivating the front passenger side front airbag
⇒ “3.11 Removing and installing front passenger airbag key switch”, page 231 .
12 - Front airbag front passenger's side
⇒ “3.15 Removing and installing airbag unit on the passenger side”, page 235 .
13 - Warning light for deactivation of the front airbag on the front passenger side

3.3 Observe the general safety instructions

for working on airbag, belt tensioner and
battery separation units (pyrotechnical
components)
WARNING
♦ Inspection, removal and installation and repair work must

only be carried out by properly qualified personnel.
♦ Only work described in this Workshop Manual must be
carried out. It is absolutely prohibited to disassemble the
airbag units.
♦ The fuel contained in pyrotechnical components is
burned, which produces gases. Furthermore, certain em‐
bodiments contain compressed gas which is used for the
gas production.
♦ This compressed gas is stored in a highly pressurised
pressure gas tank.
♦ The ignition of pyrotechnical components is carried out by
means of electrical/mechanical igniters.
♦ There are no change intervals for the airbag units.
♦ Under no circumstances use a test lamp, voltmeter or
ohmmeter for testing.
♦ Pyrotechnical components should only be checked when
installed and with a manufacturer-specified vehicle diag‐
nosis, measurement and information system.
♦ When working on pyrotechnical components and on the
airbag control unit - J234- , the earth strap of the battery
must be disconnected once the ignition is switched on.
Subsequently cover the negative terminal.
♦ After disconnecting the battery it is essential to wait 1 mi‐
nute.
♦ SWITCH ON the ignition before connecting the battery.
Nobody should be in the vehicle when the battery is con‐
nected. Exception: vehicles with the battery located in the
vehicle interior. In this case, you must not be in the range
of influence of the airbags and seat belts.
♦ If the vehicle is equipped with the Kessy system, the igni‐
tion should only be switched on after connecting the bat‐
tery using the ⇒ Vehicle diagnostic tester outside the
vehicle cockpit (the valid ignition key must be inside the
vehicle) for safety reasons. This procedure is part of the
test in the targeted fault finding.
♦ Wash your hands after touching the ignited pyrotechnical
components of the restraint system.
♦ Pyrotechnical components must not be opened or re‐
paired; always use new parts (risk of injury).
♦ Pyrotechnical components, which are damaged, must not
be re-installed.
♦ Defective airbag units of the airbag system which have not
been ignited must be returned for disposal to a specialist
company or to the importer in accordance with the instruc‐
tions of PST and environmental protection regulations.
The prescribed transport packaging must be used.
3. Airbag 225
♦ Pyrotechnical components, which have fallen on a hard

surface, must not be re-installed.
♦ Before handling pyrotechnical components of the restraint
system, for example, disconnecting the electrical plug
connection, the mechanic must discharge himself electro‐
statically. The electrostatic discharge is achieved by
touching grounded metal parts, for example, by briefly
touching the door closing mechanism.
♦ Pyrotechnical components should be installed immediate‐
ly after being removed from the transport container.
♦ If work is interrupted, place the pyrotechnical components
back in the transport container.
♦ It is not permitted to leave the pyrotechnical component
unattended.
♦ Pyrotechnical components should not be treated with
grease, cleaning agents or similar products.
♦ Pyrotechnical components should not be exposed to tem‐
peratures above 100 °C, not even for short periods.
3.4 Special instructions for driver and front

passenger airbag
WARNING
♦ Driver and front passenger airbag units in an unmounted

condition are to be deposited with the impact absorber to‐
wards the top.
3.5 Storage, transport and disposal of air‐

bag, belt tensioner and battery separa‐
tion units (pyrotechnical components)
WARNING
♦ The storage is subject to the respective national legisla‐

tion.
♦ The transport is subject to national and international leg‐
islation, in which packaging, marking, labeling, and ac‐
companying documents are regulated in detail.
♦ Non-ignited pyrotechnical components must be discarded
in the original packaging in compliance with the applicable
disposal procedure according to the national legislation!
In case you have any questions, please contact your im‐
porter.
♦ Only fully ignited pyrotechnical components may be dis‐
posed of as industrial waste.

3.6 Replacing parts of the airbag system

Accident with deployment of airbag
Note
“Compulsory registration before repair” Note regarding deploy‐

ment of airbag and non-deployment of airbag in the ⇒ Technical
Service Handbook .
Elsa ⇒
Technical Service Handbook
Technical product information ⇒
Body/equipment ⇒
Operation ⇒
Occupant protection ⇒
Airbag fire accident (safety relevant inquiry-registration docu‐
ments) ⇒
Systems
The following parts must, in principle, be replaced by new original
parts only:
♦ Central control unit for airbag system, VW 10 1).
♦ Airbag unit on the driver's side 2).
♦ Airbag unit on the front passenger's side 2).
♦ Side airbag unit on the driver's side 2).
♦ Side airbag unit on the front passenger's side 2).
♦ Seat covering 3).
♦ Head airbag driver's side 2).
♦ Head airbag front passenger's side2).
♦ Top trim panel of A pillar 4).
♦ Top trim panel of B pillar 4).
♦ Top trim panel of C pillar 4).
♦ Headlining 4).
♦ Restoring ring with slip ring 5).
♦ Driver seat belt tensioner with seat belt 2).
♦ Front passenger seat belt tensioner with seat belt 2).
♦ Seat belt tensioners with seat belts for the rear seats 2).
1) If the front and side airbag unit or head airbag unit and seat belt
tensioner have ignited, the control unit may be used again - up to
three times.
2) In the event of ignition.
3) In the event of ignition of the side airbag unit.
4) In the event of ignition of the head airbag unit.
5) In the event of ignition of the driver airbag unit.
3. Airbag 227
Replace all damaged parts if necessary (visual inspection) with

new original parts.
After the control unit and other damaged parts have been re‐
placed the control unit must be encoded again.
Accident without deployment of airbag
♦ If the airbag control indicator (K 75) is displaying no errors and
no airbag system parts are damaged, it is not necessary to
replace airbag components. Seat belts in particular must be
examined.
Registering parts of the airbag system
If a part of the airbag system is to be replaced using original parts
the self-adhesive labels with the number should be removed,
placed on the registration card part number 000 010 100 A and
sent in for registration to the customer service network (domestic)
or the importer (in the case of other countries):
♦ Central control unit for the airbag system.
♦ Airbag unit on the driver's side.
♦ Airbag unit on the front passenger's side.
♦ Side air bag unit, driver's side, with seat covering.
♦ Side air bag unit, front passenger's side, with seat covering.
♦ Acceleration sensor for side impact on the driver's side.
♦ Acceleration sensor for side impact on the front passenger's
side.
♦ Pressure sensor for side impact on the driver's side.
♦ Pressure sensor for side impact on the front passenger's side.
♦ Acceleration sensor for front collision at the lock carrier in the
engine compartment.
♦ The head airbag unit on the driver's side.
♦ The head airbag unit on the front passenger's side.
♦ Moulded headliner for head airbag.
3.7 Removing and installing the airbag con‐

trol unit
WARNING
When working on the airbag control unit , observe the general

safety instructions for working on airbag, belt tensioner and
battery separation units (pyrotechnical components).
Removing
⇒ “2.2 Centre console”, page 201 .

– Unlock the locking mechanism from the plug -1- starting from
the footwell on the front passenger side.
– Disconnect plug -1- from control unit.
– Release nuts -1- (9 Nm).
Note
To provide a better overview, the adjoining components are only

partially shown in the illustration.
– Take the control unit -2- out of the vehicle.

Installing
– Switch on ignition.
WARNING
Make sure no person is present in the vehicle.

– If the control unit has been replaced, it must be coded again
⇒ “3.8 After replacement, configure the control unit”,
page 229 .
3.8 After replacement, configure the control

unit
♦ Vehicle diagnosis, measurement and information system -
VAS- with corresponding diagnostic cable ⇒ Vehicle diagnos‐
tic tester.
♦ Diagnostic cable .
After replacing the control unit for the airbag and carrying out the
automatic test sequence using the ODIS program in the tab “Test
plan”, select the suggested test “Code control unit for airbag” (fol‐
low the in-test instructions) or select the following procedure:
– In the “ Test plan ” tab, press “ Select self-test ”.
– Select “Body”.
– Select “Assembly work on the body”.
– Select “01 - Self-diagnosable systems”.
– “Select Airbag UDS”.
– Select “function- airbag”.
3. Airbag 229
– Select “Code control unit for airbag”.
3.9 Installing and removing sensor for side

impact on the B-pillar
WARNING
Safety regulations should be observed during handling

⇒ “3.3 Observe the general safety instructions for working on
airbag, belt tensioner and battery separation units (pyrotech‐
nical components)”, page 225 .
Removing
– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.
27 .
– Remove bottom trim panel of B pillar
page 267 .
– Remove the screw - 1 - (9 Nm) and remove the sensor - 2 -.
Installing
WARNING
Pay attention to the sequence when connecting the battery ⇒

Electrical System; Rep. gr. 27 .
3.10 Installing and removing sensor for side

impact on the C-pillar
WARNING
Safety regulations should be observed during handling

Removing
27 .
– Remove wheel house trim panel
⇒ “3.8.2 Removing and installing wheel house trim panel”,
page 272 .


– Remove the screw - 1 - (9 Nm) and remove the sensor - 2 -.
Installing
WARNING

3.11 Removing and installing front passenger

airbag key switch
WARNING
Observe the general safety instructions for working on airbag,

belt tensioner and battery separation units (pyrotechnical com‐
ponents)
The switching off and on is undertaken only when the ignition
is switched off.
Removing
27 .
– Remove the glove compartment on front passenger's side
249 .
– Disconnect the plug connection of the front passenger airbag
key switch.
3. Airbag 231
– Release catches (Pos. 2 and 3) and unscrew key switch for

front passenger's airbag (Pos. 1) out of the front passenger's
side glovebox.
Installing
– Clip the key switch into glovebox on the front passenger side.
– Connect the plug connection of the front passenger airbag key
switch.
– Install the glove compartment on the front passenger side
249 .
– Connect earth strap of battery ⇒ Electrical System; Rep. gr.
27 .
WARNING
Nobody should be in the vehicle when the battery is being con‐

nected.
3.12 Summary of components of steering wheel

1 - Steering wheel
Removing
– Remove driver's airbag

unit
⇒ Item 3 (page 233) .
– Position the steering

wheel to centre position
(wheels in straighta‐
head position).
– Mark the opposite posi‐

tion of the steering
wheel and the shaft -4-
with a line, as long as
this position is not facto‐
ry-marked.
– Remove the steering

wheel from the steering
column.
Installing

in reverse order.
2 - 30 Nm + 90°.
– Can be used up to five
times, then replace.
– Mark with a dot after

each mounting.
3 - Airbag unit
– Removing and installing
⇒ “3.13 Removing and installing driver airbag unit”, page 233 .
4 - Steering wheel shaft
3.13 Removing and installing driver airbag

unit
WARNING
Observe the general safety instructions for working on airbag,

belt tensioner and battery separation units (pyrotechnical com‐
ponents)
Observe the special instructions for driver and front passenger
airbag
⇒ “3.4 Special instructions for driver and front passenger air‐
bag”, page 226 .
3. Airbag 233
Removing
27 .
– Put steering wheel in the lowest position.
– Pull out steering wheel fully up to the limit stop.
– Turn steering wheel until one of the holes -arrows- is located
at the top.
– Lever off the spring -arrow A- in -the direction of arrow B- using

a screwdriver (max. total length of the screwdriver approx. 170
mm, width approx. 5 mm).
Note
When unhooking the spring, push away airbag unit from steering
wheel.
– Repeat process for the second spring.

– Carefully remove airbag unit from the steering wheel and fold
back.

– Disconnect plug connection -1- and if necessary -2- (only for

vehicles with multi-function steering wheel).
– Lay aside the airbag unit in such a way that the impact ab‐
sorber points upwards.
Installing
WARNING
Nobody should be in the vehicle when the battery is being con‐

nected.
Note
If the airbag control indicator - K75 - indicates a fault after as‐

sembly, the event memory must be queried ⇒ Vehicle diagnostic
tester.
3.14 Removing and installing restoring ring

with slip ring
– Removing and installing ⇒ Electrical System; Rep. gr. 94 ;
Steering column combination switch; removing and installing
restoring ring with slip ring in the steering column combination
switch .
3.15 Removing and installing airbag unit on

the passenger side
Removing
WARNING

nical components)
♦ Observe the special instructions for driver and front pas‐
senger airbag
⇒ “3.4 Special instructions for driver and front passenger
airbag”, page 226 .
WARNING
When electrostatic discharges occur, there is a risk of the air‐

bag being activated unintentionally. Therefore, the mechanic
must discharge himself electrostatically before separating the
ignition and earth lead. This occurs, for example, by briefly
touching the body or the door closing mechanism.
3. Airbag 235

– Remove the glove compartment
249 from the dash panel -1-.
– Disconnect the plug -4- from the airbag unit -2-.

– Take the airbag unit -2- out of the vehicle.
Installing
– Switch on ignition.
WARNING
Make sure no person is present in the vehicle.


Note

tester.
3.16 Removing and installing side airbag
WARNING
♦ Observe the safety instructions for pyrotechnic compo‐

nents
♦ Observe the disposal instructions for pyrotechnic compo‐
nents
⇒ “3.5 Storage, transport and disposal of airbag, belt ten‐
sioner and battery separation units (pyrotechnical com‐
ponents)”, page 226 .
Removing
– Remove front seat backrest.
– Remove backrest cover
⇒ “1.3 Removing and installing the cover and the upholstery
of the front seat backrest”, page 301 .
– Disconnect plug connection -5- for side airbag unit -4-.
– Unclip catch -1- for side airbag -4- from the seat rest rack -2-.
– Remove the airbag unit -4- from the seat rest rack -2-.
3. Airbag 237
Installing
WARNING

nical components) ⇒ page 225 .
♦ Prior to the handling of pyrotechnical components (for ex‐
ample, disconnecting the electrical plug connection) the
person who carries out this operation must “discharge
himself electrostatically”. For this purpose, briefly touch
the door lock, for example.
Note
♦ Make sure the plug connection is pushed in as far as it can go

and audibly clicks into place.
♦ Make sure that the electric cables are not trapped.

WARNING
Switch on the ignition before connecting the battery. Improper

handling of pyrotechnic components may lead to unwanted
deployment after the battery has been connected. Nobody
should be inside the vehicle when the battery is being connec‐
ted.
– Work procedure for connecting the battery ⇒ Electrical sys‐

tem; Rep. gr. 27 ; Disconnecting and re-connecting the bat‐
tery .
Note

tester.
3.17 Head airbag
3.17.1 Summary of components - head airbag
1 - Anti-twist protection line

❑ Used to protect against
twisting during installa‐
tion.
❑ It must be visible over
the entire length of the
airbag in the installed
condition.
2 - Head airbag
❑ On the driver's and front
passenger's side with
airbag igniter.
WARNING
Observe the safety in‐
structions for pyrotech‐
nic components
⇒ “3.3 Observe the gen‐
eral safety instructions
for working on airbag,
belt tensioner and bat‐
tery separation units (py‐
rotechnical compo‐
nents)”, page 225 .

installing head airbag
with ignition for head air‐
bag driver's side/front
passenger side N251 /
N252 ”, page 240
3 - Screw
❑ Always use a new screw
after disassembly.
3. Airbag 239
❑ 5.2 Nm.
4 - Retaining clip
5 - Retaining clip
3.17.2 Removing and installing head airbag

with ignition for head airbag driver's
side/front passenger side - N251 - / -
N252 -
Removing
WARNING

nents
♦ Observe the additional safety instructions for the head air‐
bag
⇒ “3.4 Special instructions for driver and front passenger
airbag”, page 226 .
♦ Observe the disposal instructions for pyrotechnic compo‐
nents
⇒ “3.5 Storage, transport and disposal of airbag, belt ten‐
sioner and battery separation units (pyrotechnical com‐
ponents)”, page 226 .
– Turn off the ignition and disconnect the battery earth strap ⇒
Electrical System ; Rep. gr. 27 ; Disconnecting and recon‐
necting the battery .
– Lower the moulded headliner (not necessary to remove from
the vehicle)
⇒ “7.1 Removing and installing moulded headliner”,
page 282 .
– Remove clips -4- from the head airbag.
– Use e.g. a set of pointed pliers for unclipping. Insert the pliers
-5- into openings -1 and 2-. Press gently until the catches -3-
are clear.
– Slide the clips out of the body.

– Unclip the holding clamp -1- from the A pillar.
WARNING
Prior to the handling of pyrotechnical components (for exam‐

ple, disconnecting the electrical plug connection) the person
who carries out this operation must “discharge himself elec‐
trostatically”. For this purpose, briefly touch the door lock, for
example.
3. Airbag 241
– Remove plug -1- and pull out from head airbag unit -2-
-arrow-.
– Remove the screw -3- from the head airbag.
– First unhook the head airbag -1- at the front from the body
-arrow B- and push out towards the rear.
– Unhook the rear head airbag from the body -arrow A- and re‐
move.
Installing
WARNING

nents
♦ Observe assembly sequence.
♦ Prior to the handling of pyrotechnical components (for ex‐
ample, disconnecting the electrical plug connection) the
person who carries out this operation must “discharge
himself electrostatically”. For this purpose, briefly touch
the door lock, for example.
– First suspend the head airbag -1- at the rear on the body
-arrow A- and push towards the front.
– Attach to the body at the front -arrow B-.

– Screw in screw - 1 - (5.2 Nm).
– Rotate the rear retaining clip -1- downwards by 90° -arrow-

and engage in the body.
– Press in the remaining retaining clips of the head airbag until
they audibly lock into place, beginning at the gas generator
towards the front and rear.
– Carry out a tensile test on the retaining clips and check them
to make sure they are locked completely.
– Mount connector on head airbag.
– Push connector in up to the stop until the plug lock engages.
– Check whether the anti-twist protection line (coloured longitu‐
dinal stripes on the airbag unit) is visible over the entire length
and is straight. This ensures that the airbag has not become
twisted.
WARNING
Observe work procedure for connecting the battery ⇒ Electri‐

cal system; Rep. gr. 27 ; Disconnecting and re-connecting the
battery .
Note

tester.
3. Airbag 243
70 – Trim, insulation
1 Dash panel
1.1 Removing and installing the dash panel

Summary of components of dash panel
1 - Dash panel
2 - Screw
Nm.

Removing
Note
Disconnect battery earth strap ⇒ Electrical System; Rep. gr. 27 .
– Remove driver's airbag unit

⇒ “3.13 Removing and installing driver airbag unit”,
page 233 .
244 Rep. gr.70 - Trim, insulation

– Remove the steering wheel

⇒ “3.12 Summary of components of steering wheel”,
page 232 .
– Remove steering column trim panel
⇒ “1.3 Removing and installing the steering column trim pan‐
el”, page 251 .
– Removing dash panel insert ⇒ Electrical System; Rep. gr.
90 .
– Remove light switch ⇒ Electrical System; Rep. gr. 96 .
– Pull plug out of the daytime running light switch and the head‐
light range control adjuster ⇒ Electrical System; Rep. gr. 96 .
– Remove cover of fuse box.
– Unscrew screws for fuse box and unhook it ⇒ Electrical Sys‐
tem; Rep. gr. 97 .
– Remove the lateral dash panel covers -1 and 2- e.g. using the
disassembly wedge -3409-.
– Remove the glove compartment
249 .
– Unclip frame -1-.

– Unscrew screws for radio or navigation (depending upon ve‐
hicle equipment) ⇒ Electrical System; Rep. gr. 91 .
– On vehicles without radio or navigation, remove the storage
compartment of the middle dash panel.
Air conditioning system with manual control
– Remove the heater control ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
Automatic air conditioning system
– Removing the control and display unit for air conditioning sys‐
tem with control unit ⇒ Heating, Air Conditioning; Rep. gr. 87 .
1. Dash panel 245

– Remove the sunlight penetration photosensor ⇒ Heating and

Air Conditioning; Rep. gr. 87 .
– Remove vents, right, left (pull out sender plugs) and centre
vent (disconnect plug connections for hazard warning light
switch and airbag deactivation warning light) ⇒ Heating, Air
Conditioning; Rep. gr. 87 .
Vehicles without air conditioning system
– Remove control for heating and fresh air ⇒ Heating, Air Con‐
ditioning; Rep. gr. 80 .
– Remove the right, left and centre vents (disconnect the plug
connection for the switch of the hazard warning light system
and the warning light for airbag switch-off function) ⇒ Heating,
Air conditioning; Rep. gr. 87 .
– Remove the top trim panel of the pillar A
263 .
– Remove screw -1- (1,5 Nm).

1. Dash panel 247

– Remove fixing screws for front passenger's airbag unit - 1 -

(9 Nm).
– Disconnect airbag unit plug connection (depending on vehicle
equipment).
– Pull the dash panel out of the supports in the transition area
to the windscreen.

– Remove the dash panel - 1 - from the vehicle with the assis‐
tance of a second mechanic.
Installing
Note
1.2 Removing and installing the glove com‐

partment
Removing
– Remove the lateral dash panel cover on the front passenger
side.
– Release screws -arrows- (1.5 Nm).
– Release screws -1 and 2- in the glove compartment (1.5 Nm).
– Release screws -3- and -4- (1.5 Nm).
1. Dash panel 249

– Loosen the glove compartment from the dash panel.

– Disconnect plug connection for front passenger airbag deac‐
tivation.
– Detach intake hose for AC glove compartment.
– Detach the plug from the glove compartment light.
– Remove glove compartment from vehicle.
Installing
Note

1.3 Removing and installing the steering

column trim panel
Removing
– Remove driver's airbag unit
⇒ “3.13 Removing and installing driver airbag unit”,
page 233 .
– Remove the steering wheel
⇒ “3.12 Summary of components of steering wheel”,
page 232 .
– Slacken the fixing lever of the steering wheel adjustment.
– Pull out the steering column and press it down.
– Loosen the frame with the top part of the steering column trim
panel -1- from the supports.
– Remove the top part of the steering column trim panel -1-.
– Release the screws from the bottom part of the steering col‐
umn trim panel - 1 - (1.5 Nm).
– Loosen the bottom part of the steering column trim panel -2-
from the supports.
Installing
1.4 Removing and installing the decorative trim of the dash panel
Removing
– Remove vent ⇒ Heating, Air Conditioning; Rep. gr. 87 .
– Carefully unclip the decorative trims - 2 and 3 - with e.g. a
dismantling wedge -3309- .
1. Dash panel 251

Installing
– Slide decorative trim into the recesses in the dash panel.
– Press in the panel until the clips click into place.
– Install vents.
1.5 Removing and installing the cross mem‐

ber for the dash panel
Removing
– Removing dash panel
– Release screw -2- (20 Nm) and remove support -1-.

– Removing the left footwell vent on the driver side ⇒ Heating,

Air Conditioning; Rep. gr. 80 .
– Remove the steering column assembly from the crossmember
⇒ Chassis; Rep. gr. 48 .
– Remove wiper arms and wiper motor ⇒ Electrical System;
Rep. gr. 92 .
– Remove the plenum chamber cover
⇒ “1.8 Plenum chamber cover”, page 13 .
1. Dash panel 253

– Release the screw -1- in the plenum chamber on the driver's

side (20 Nm).
– Press out expanding pins -2-.

– Pull out expanding rivets.
– Remove the intermediate piece -3- ⇒ Heating, Air Condition‐
ing; Rep. gr. 80 .
– Remove air guide duct -1- ⇒ Heating, Air Conditioning; Rep.
gr. 80 .
– Remove other components attached to the cross member if
necessary.


– Slacken wiring loom attachment from cross member.

Installing
Note
1. Dash panel 255

1.6 Removing and installing impact absorb‐

ers
Removing
– Assignment ⇒ Electronic Catalogue of Original Parts .
– Removing dash panel
– Removing foot control ⇒ Rep. gr. 46 ; Brake systems; re‐
moving and installing bearing bracket .
– Removing clutch pedal ⇒ Rep. gr. 30 ; Clutch operation; re‐
moving and installing clutch pedal .
– Unscrew nuts Pos. -2-.
– Slide out strut from opening in central pipe.
– Remove strut.
Installing

2 Door and side trim panels
2.1 Removing and installing the front door

trim panel
Removing
– Remove trim -2- for power window lifter ⇒ Electrical System;
Rep. gr. 96 and disconnect plugs -3 and 4-.
– Unclip the trim - 6 - e.g. Using the disassembly wedge -
T10383, 3409- .
– Turn the nut -7 - by 90° at the bottom side using the open-end
spanner SW 10 and unlock the catch peg.
2. Door and side trim panels 257

Caution
When releasing the door trim panel, there is the risk that dam‐
age may occur on the fixing elements! To prevent this, the
specified location and order of the clip connections to be loos‐
ened must absolutely be kept when removing the door trim
panel!
– Loosen the door trim panel in the -specified order - out of the
clip connections. To do this, e.g. use the wide plastic wedge -
T10383 / 1, T10383- .
– Pull the door trim panel towards the top and out of the window
channel.

– Push the Bowden cable -3- on the inside of the door trim panel
out of the inner door control -2- in -direction of arrow- and un‐
clip the end piece -1-.
– Disconnect the electrical plug connections from the door trim
panel depending on the vehicle equipment.
Installing
Note
2.2 Removing and installing the rear door

trim panel
Removing
– Carefully clip the trim -3- out of the door trim panel e.g. using
the disassembly wedge - T10383, 3409- .


– Turn the nut -4 - by 90° at the bottom side using the open-end
spanner SW 10 and unlock the catch peg.
– On vehicles with window cranks, remove the window crank.
Slide the spacer ring -1- in -direction of arrow- and detach the
window crank from the drive.
Caution
When releasing the door trim panel, there is the risk that dam‐
age may occur on the fixing elements! To prevent this, the
specified location and order of the clip connections to be loos‐
ened must absolutely be kept when removing the door trim
panel!
– Loosen the door trim panel in the -specified order - out of the
clip connections. To do this, e.g. use the wide plastic wedge -
T10383 / 1, T10383- .

– Pull the door trim panel towards the top and out of the window
channel.
– Push the Bowden cable -3- on the inside of the door trim panel
out of the inner door control -2- in -direction of arrow- and un‐
clip the end piece -1-.
– Disconnect the plug connections of the wiring looms from the
door trim panel depending on the vehicle equipment.
Installing
Note

– On vehicles with manual window lifters, the installation posi‐

tion of the window crank -1- on a closed crank pulley is parallel
to the pull handle -2-.
– The deviation of the window cranks to each other may only be
a maximum of 6 °.

3 Trim panels of pillars
3.1 Removing and installing top trim panel

of pillar A
Removing
– Unclip the trim panel of the A pillar -1- out of the supports of
the A pillar starting at the top.
Installing
Note
♦ Before the installation, check all the fixing elements for dam‐
age, if necessary replace.
♦ Ensure that the trim panel is located in the double-braided strip
of the door seal after the installation.
3. Trim panels of pillars 263

3.2 Removing and installing bottom trim

panel of pillar A on the driver's side
Removing
– Remove the operating lever for the front flap (Pos. 1)
⇒ “1.9.2 Removing and installing”, page 31 .
– Unclip the door sill panel in the transition area to the trim panel
of the A pillar out of the supports in the body.
– Remove the straddling dowel -2-.
– Pull the trim panel -3- towards the inside and out of the sup‐
ports in the body.
Note
Before the installation, check the straddling dowel -2- for damage, replace if necessary.
Installing

Note
Ensure that the trim panel is located in the double-braided strip

3.3 Removing and installing bottom trim

panel of pillar A on the front passenger
side
Removing
– Unclip the door sill panel in the transition area to the trim panel
of the A pillar out of the supports in the body.
– Release the catches -1- and pull the trim -2- towards the inside
and out of the supports in the body.
Installing

Note
♦ Ensure that the trim panel is located in the double-braided strip
3.4 Removing and installing top B-pillar trim

panel
Removing
– Unclip the cover -3- for the screw marked or unmarked with
“airbag” (depending upon vehicle equipment).
– Loosen the trim panel -1- out of the catches -5- and remove it
from the B pillar -6-.
– Push the trim panel -1- at the top end out of the supports in
the roof.

– Release screw for front seat belt -1- (40 Nm).

– Pull the seat belt through the opening in the trim panel.
Installing
– After attaching the trim panel, ensure that the trim panel is
located in the double-braided strip of the door seal.
Note
♦ On vehicles with seat belt height adjuster, ensure before fas‐
tening that the seat belt height adjuster is located at the shell
and the slider of the seat belt height adjuster is in the top po‐
sition at the trim panel.
♦ After the installation has been performed, carry out a func‐
tional test of the seat belt height adjuster.
♦ Make sure that the seat belt is correctly positioned and has
unobstructed movement.
3.5 Removing and installing bottom B-pillar

trim panel
Removing
– Run the seat belt -2- through the opening in the trim panel.
– Slacken the bottom trim panel -2- at the top end out of the
catch -1- in -direction of arrow A-.
– Slacken the bottom trim panel -2- at the bottom end out of the
catch -3- in -direction of arrow B-.

Installing
– After installing the trim panels, ensure that the trim panels are
located in the double-braided strip of the door seal.
– Check whether the bottom B-pillar trim panel and the door sill
panel are clipped together and fitted.
Note
♦ On vehicles with seat belt height adjuster, ensure before in‐
stalling that the seat belt height adjuster is located at the shell
and the slider of the seat belt height adjuster is in the top po‐
sition at the trim panel.
♦ After the installation has been performed, carry out a func‐
tional test of the seat belt height adjuster.
♦ Make sure that the seat belt is correctly positioned and has
unobstructed movement.

3.6 Removing and installing trim panel of

pillar C
Removing
– Loosen the C-pillar trim panel -1- in the front area out of the
double-braided strip of the door seal.
– Loosen from the tailgate seal in the rear area.
– Loosen the trim panel from the retaining clips -2-.
– Push the guides of the C-pillar trim panel out of the luggage
compartment trim panel and take the trim panel out of the ve‐
hicle.
Installing
Note

– After installing the trim panel, ensure that the trim panel is lo‐
cated in the double-braided strip of the door seal.
3.7 Removing and installing C and D pillar trim panels (Spaceback)
Removing
– Remove luggage compartment side trim panel
⇒ “6 Removing and installing side luggage compartment trim
panel”, page 281 .
– Release the catches -2-.
– Release catch -5-.
– Unclip brackets -4-.
– Unclip brackets - 3 -.
– Unscrew from guide from the guide bolts - 4 -.
– Push downwards out of the openings in the upper area of the
trim.
Installing

3.8 Door sill panel and wheel house trim

panel
3.8.1 Removing and installing door sill panel

Removing
page 295 .
– Remove wheel house trim panel
⇒ “3.8.2 Removing and installing wheel house trim panel”,
page 272 .
– Remove clips -1-.
– In the rear area, unclip the clip - 4 - and the retaining clip
- 2 - of the door sill panel - 3 -.
– Loosen the door sill panel -3- from the bottom trim panel of B-
pillar.
– In the front area, unclip all the retaining clips - 2 - of the door
sill panel - 3 -.
– Remove the door sill panel - 3 - from the vehicle.

Installing
– Ensure that the door sill panel is placed in the double-braided
strip of the door seal.
Note
3.8.2 Removing and installing wheel house

trim panel
Note
To provide a clearer illustration, the seat bench and the backrest

are not shown in the illustration.

Removing
– Removing the rear seat bench
– Remove top trim panel of pillar C
⇒ “3.6 Removing and installing trim panel of pillar C”,
page 269 .
– While doing so, loosen the retaining clips -2- out of the sup‐
ports of the body.
– Take the wheel house trim panel -1- out of the vehicle.
Installing
Note
♦ Before installation, check all the fixing elements for damage, replace if necessary.
♦ Ensure that the wheel house trim panel is placed in the double-braided strip of the door seal after the
installation.

4 Tailgate trim panel
4.1 Removing and installing tailgate trim panel
Removing
– Release the screw - 6 - (2.5 Nm) and remove the pull handle
- 5 -.
– Remove cover for rear window wiper motor ⇒ Electrical Sys‐
tem; Rep. gr. 92 .
– Unclip the plastic clips in sequence.
Installing

Note
Before the installation, check all the fixing elements for damage, if necessary replace.
4.2 Removing and installing the tailgate trim panel (Spaceback)
Removing
– Release the screw - 8 - (2.5 Nm) and remove the pull handle
- 7 -.
– Unclip the plastic clips - 5 - in succession.
– Take the trim - 6 - out of the vehicle.
– Cover for wiper motor - 4 - .
– Expanding rivet - 3 -.
– Riveted nut - 2 - .
– Pull handle carrier - 1 - .
Installing
4. Tailgate trim panel 275

Note
Before the installation, check all the fixing elements for damage, if necessary replace.

5 Luggage compartment trim panels
5.1 Removing and installing the tailgate/lug‐

gage compartment cover
Removing
– Fold up the base of the luggage compartment floor.

– Removing body-bound rivet -4-.
– Do not remove caps for screws -2-. They only cover the screws
for the latch strikers of the tailgate.
– Loosen retaining clips -3-.
– Remove tailgate/luggage compartment cover -1- upwards
from lock carrier.
Installing
5. Luggage compartment trim panels 277

Note
– Ensure that the tailgate/luggage compartment cover is located

in the double-braided strip of the tailgate seal after the instal‐
lation.
5.2 Removing and installing top part of side luggage compartment trim panel
1 - Top part of side luggage

compartment trim panel.
Removing
– Remove luggage com‐

partment cover.
– Remove the rear deflec‐

tion fitting
stalling the outer rear
seat belts”, page 216 .
– Remove top trim panel

of pillar C
stalling trim panel of pil‐
lar C”, page 269 .
– Remove wheel house

trim panel
installing wheel house
trim panel”, page 272 .
– Remove luggage com‐

partment light - 4 - ⇒
Electrical System; Rep.
gr. 96 (left side only).
– Unclip the trim panel out

of the supports of the
body.
– Run the seat belt

through the trim panel.
Installing
2 - Expanding nut
3 - Screw
4 - Luggage compartment light

5.3 Removing and installing side luggage compartment trim panel
Removing
– Remove the tailgate/luggage compartment cover
⇒ “5.1 Removing and installing the tailgate/luggage compart‐
ment cover”, page 277 .
page 295 .
– Remove top part of side luggage compartment trim panel
– Unclip retaining clips - 2 - from the trim panel - 1 -.
– Remove screw -3- (1.2 Nm) for fixing hooks -4-.
– Remove the trim panel -1- in the front area from the locking
clamp and the backrest frame.
– Loosen the trim panel -1- towards the inside out of the support.
5. Luggage compartment trim panels 279

– Take the trim panel -1- out of the luggage compartment.

– Position -5- expanding nut.
Installing
Note

6 Removing and installing side luggage compartment trim panel
1 - Fixing hooks
2 - Screw - 2.5 Nm
3 - Expanding nut
4 - Fixing hooks
5 - Screw - 1.2 Nm
6 - Retaining clip
7 - Side luggage compartment
trim panel
Removing
– Removing the rear seat

bench
⇒ “3 Removing and in‐
stalling backrests”,
page 298 .
– Remove rear seat

bench
stalling the rear seat
bench”, page 295 .
– Remove the tailgate/

luggage compartment
cover
stalling the tailgate/lug‐
gage compartment cov‐
er”, page 277 .
– Remove the rear deflec‐

tion fitting
stalling the outer rear
seat belts”, page 216 .
– Remove
⇒ Item 6 (page 281) clip.
– Remove fixing hooks ⇒ Item 4 (page 281) .
– Remove fixing hooks ⇒ Item 1 (page 281) .
– Unclip the trim panel.
– Disconnect the plug connection form the luggage compartment light of 12 V socket (depending in the
equipment installed in the vehicle).
– Run the seat belt through the trim panel.
Installing
6. Removing and installing side luggage compartment trim panel 281

7 Moulded headliner
7.1 Removing and installing moulded head‐

liner
Removing
– Removing sun visors
⇒ “2.6 Removing and installing the sun visor”, page 208 .
– Remove the top trim panel of the pillar A
263 .
– Loosen the top trim panel of pillar B
page 266 .
– Remove the trim panels of C-pillar
⇒ “3.6 Removing and installing trim panel of pillar C”,
page 269 .
– Remove the recessed handles of the roof
⇒ “3.1 Removing and installing the recessed handles of the
roof”, page 210 .
– Remove top parts of side luggage compartment trim panel
– Fold back backrests.
– Put the steering wheel into the lowest position by means of the
adjustment functions.
Vehicles fitted with a manual gearbox
– Engage the “2nd gear” with the shift lever.
Vehicles with an automatic gearbox
– Select the driving position “S” with the selector lever.
Vehicles with interior monitoring
– Disconnect the motion sensor and the sensor for vehicle in‐
clination (depending upon vehicle equipment) ⇒ Electrical
System; Rep. gr. 96 .
All vehicles
– Remove screws -2- (2 Nm) of front interior light ⇒ Electrical
System; Rep. gr. 96 .
– Remove the rear interior light ⇒ Electrical System; Rep. gr.
96 .

– Loosen rear moulded headliner -1- and unclip clip -2-.
– Loosen the moulded headliner -1- out of the door seals.

– Carefully lower the moulded headliner -1- with the assistance
of a 2nd mechanic (risk of fracture).
– Remove the moulded headliner through the tailgate opening.

Installing
7. Moulded headliner 283

Note
– Ensure that the moulded headliner -1- is located in the double-

braided strip of all the door seals after the installation.
7.2 Removing and installing the dampings

and roof reinforcements
Removing
⇒ “7.1 Removing and installing moulded headliner”,
page 282 .
– Cut the dampings and the roof reinforcements - 1 and 2 - into
strips of approx. 9 cm width (Pos.3), using a carpet knife
- (dotted lines) -.
– Detach the strips -3- from the roof.
– Cut back the glue residues - 4 -.

Installing
Note
When installing the dampings and the roof reinforcements, pay

attention to the handling instructions of the glue.
– Use the hand pressure gun to apply the glue - D 190 MKD A3-
on the front and rear -2- damping and roof reinforcements
-1-.
– Apply the glue beads according to the following dimensions:
♦ Dimension a = 33 mm ± 2 mm
♦ Dimension b = 25 mm ± 2 mm
♦ Dimension c = 92 mm ± 2 mm
– Fully press the dampings and the roof reinforcements
-1 and 2- against the roof.
7. Moulded headliner 285

72 – Seat frames
1 Front seats
1.1 Removing and installing front seat

Removing
– Put the seat into the foremost position by means of the longi‐
tudinal adjustment.
– Unscrew the rear screws -1 and 3-.
– Put the seat into the rearmost position by means of the longi‐
tudinal adjustment.
– Unscrew the front screws -2 and 4-.
– Remove seat from vehicle.
286 Rep. gr.72 - Seat frames

Caution
If the seat is lifted out of the vehicle or transported, it must not

be touched at the component parts. These include the belt
buckle, the lever for the longitudinal seat adjustment, the seat
height adjustment lever and the seat trim panels. This is nec‐
essary to avoid damage.
Installing
– Insert the seat into the corresponding hole in the floor via a
centering pin - 5 - on the tunnel side.
– Put the seat into the rearmost position by means of the longi‐
tudinal adjustment.
– Tighten the front screw -4- on the tunnel side (40 Nm).
– Tighten the front screw -2- on the rail side (40 Nm).
– Put the seat into the foremost position by means of the longi‐
tudinal adjustment.
– Tighten the rear screw -3- on the tunnel side (40 Nm).
– Tighten the rear screw -1- on the rail side (40 Nm).
1. Front seats 287

WARNING
If a thread in the support panel of the seat crossmember is

damaged during the installation, it is not permitted to rework
the damaged thread! In this case, the support panel of the seat
crossmember must be replaced.
If there is a thread damage in the support panel of the seat cross‐

member:
– Replace the affected support panel of the seat crossmember
⇒ Body Repairs; Rep. gr. 51 .
1.2 Removing and installing the seat up‐

holstery on the rail side (seat without
height adjustment)
Removing
– Lever the cap -5- out of the backrest adjustment lever -4-.
– Detach the backrest adjustment lever -4-.
Note
The backrest adjustment lever -4- cannot be detached from the adjustable axle without being destroyed.
– Open the bottom fixing latch of the seat upholstery -2- and
press the support from the wire strap.
– Loosen the seat upholstery -2- from the seat rack -1- and re‐
move the seat upholstery.

Installing
Note
1.3 Removing and installing the seat up‐

holstery on the rail side (seat with height
adjustment)
Removing
– Lever the cap -5- out of the backrest adjustment lever -6-.
– Detach the backrest adjustment lever -6-.
1. Front seats 289

Note
The backrest adjustment lever -6- cannot be detached from the adjustable axle without being destroyed.
– Pull up the handle -2- and press the metal tab of the retaining
clip -3- towards the inside using a small screwdriver. Pull down
the handle of the adjusting lever -4-.
Note
To provide a better overview, the retaining clip is shown in the illustration in its removed condition.
– Remove retaining clip -3- from adjusting lever -4-.
– Open the bottom fixing latch of the seat upholstery -2- and
press the support from the wire strap.

– Loosen the seat upholstery -2- from the seat rack -1- and re‐
move the seat upholstery.
Installing
Note
1.4 Removing and installing the operating

lever of the seat height adjustment
Removing
– Remove the seat trim panel on the rail side (seat with height
adjustment)
⇒ “1.3 Removing and installing the seat upholstery on the rail
side (seat with height adjustment)”, page 289 .
– Release the screws -1- (4.5 Nm) and remove the operating
lever -2-.
Installing
1.5 Removing and installing the seat trim

panel on the tunnel side
Removing
– Remove the front belt buckle
⇒ “1.3 Removing and installing the front seat belt buckle”, page
214 .
– Loosen the seat upholstery -2- from the supports in the seat
rack -3- and remove the seat upholstery.
1. Front seats 291

Installing
1.6 Removing and installing the grip for the

seat height adjuster
Removing
Note
To provide a better overview, the retaining clip is shown in the

illustration in its removed condition.
– Pull up the handle -1- and press the metal tab of the retaining
clip -2- towards the inside using a small screwdriver. Pull down
the handle of the adjusting lever -3-.

– Remove retaining clip -2- from adjusting lever -3-.

Installing
Note
Before the installation, check the retaining clip -2- for damage,
replace if necessary.
1.7 Removing the headrest guides

Removing
Note
To provide a better overview, the headrest guides are shown in

their removed condition.

214 .
– Remove the seat trim panel on the tunnel side
⇒ “1.5 Removing and installing the seat trim panel on the tun‐
nel side”, page 291 .
– Remove the seat trim panel on the rail side:
♦ Seat without height adjustment
side (seat without height adjustment)”, page 288 .
♦ Seat with height adjustment
– Remove the cover and the upholstery of the front seat backrest
⇒ “1.3 Removing and installing the cover and the upholstery
of the front seat backrest”, page 301 .
– Unlock the locking mechanism -arrow A- of the headrest guide
with the button -1-.
– Pull the headrest guide out of the backrest - 3 - with the button
- 1 -.
– Unlock the locking mechanism -arrow B- of the headrest guide
-2-.
– Pull the headrest guide -2- out of the backrest -3-.
1. Front seats 293

Installing

2 Rear seats
2.1 Removing and installing the rear seat

bench
Removing
– Grip on both sides with both hands under the seat bench
- 1 - in the area of the mounting grommet - 2 - and pull up
forcefully and with a sudden motion in the
-direction of arrow-.
– Guide the seat bench -1- in -direction of arrow- on both sides

out of the crash hooks -2- on the left and right.
– Disconnect the plug connections for heating prior to removing
the seat bench (depending on the vehicle equipment).
– Take the seat bench -1- out of the vehicle.
2. Rear seats 295

Installing
– Connect the plug connections for seat bench heating (de‐
pending on vehicle equipment).
– Before assembling the seat bench - 2 - replace the mounting
grommets as these parts are not designed for reuse.

– Insert seat bench in - direction of arrow - on both sides with

the crash hooks - 1 - into the mounting grommets - 2 - until
they audibly click into place.
Note
Check seat bench for firm seating after installing.
2. Rear seats 297

3 Removing and installing backrests

Removing
– Remove deflection fitting below for the middle safety belt
⇒ “1.8 Removing and installing the rear double belt buckle”,
page 219 .
– Unlock both backrest parts and fold over.
– Remove cap for clamp.
– Release the screw -1- (9 Nm) and remove the clamp -3- from
the support -2-.
– Unhook backrest from the middle positions -arrow A-.

– Push the seat backrest out of the bolts -arrow B-.
– Disconnect the plug connections for heating prior to removing
the backrest (depending on the vehicle equipment).
Installing

74 – Seat - padding, covers

1 Covers and upholstery of the front
seats
1.1 Tools
♦ Upholstery retaining clip pliers, e.g. - V.A.G 1634-
1.2 Removing and installing the cover and

the upholstery of the front seat cushions
Removing
214 .
– Unhook the clamping section -1- from the seat rack -2-.
1. Covers and upholstery of the front seats 299

– Fold up the cover -2- all around and remove the upholstery
retaining clips -1-.
– Remove the cover - 2 - from the upholstery - 3 -.
– Remove the front seat cushion -1- from the seat rack -2-.
Installing
– Attach the cover -1- with new upholstery retaining clips -2-, at
the indicated points -3-, using the upholstery clip pliers - V.A.G
1634- .
300 Rep. gr.74 - Seat - padding, covers

1.3 Removing and installing the cover and

the upholstery of the front seat backrest
Removing
Note
♦ When disassembling, ensure that the backrest upholstery is

not damaged.
♦ The removal and the installation of the components is descri‐
bed for the left seat. The same applies for the removal and the
installation of the components for the right seat.

– Pull out the headrest.
214 .


– Unhook the clamping section in the bottom area of the cover.
– Roll up the cover -1- at the upholstery -3- and while doing so
remove all the upholstery retaining clips -2-.
– Roll up the cover on the backside -2- at the upholstery -3- and
while doing so remove both upholstery retaining clips -1-.
– Roll up the cover -2- further and remove via the two headrest
guides.

– Pull the upholstery -1- over both headrest guides and remove
it from the backrest frame -2-.
Installing
– Slide the upholstery onto the backrest frame.

– Attach the cover -1- with new upholstery retaining clips -2-, at
the indicated points -3-, using the upholstery clip pliers - V.A.G
1634- .

2 Rear covers and seat upholstery
2.1 Tools
♦ Upholstery retaining clip pliers, e.g. - V.A.G 1634-
2.2 Removing and installing cover and seat

upholstery
Removing
page 295 .
– Separate all the upholstery retaining clips - arrow - all around
the underside of the seat bench.
2. Rear covers and seat upholstery 305

– Roll up the cover -1- all around.

– Remove all the upholstery retaining clips -3-.

Installing
– Attach the cover - 1 - with new upholstery retaining clips - 3 -
to the upholstery - 2 - using the upholstery clip pliers - V.A.G
1634- .

2.3 Removing and installing entire cover

and backrest upholstery
Removing
– Open the double-braided strip -2- of the cover -1- on the rear
side of the backrest and fold up in -direction of arrow B-.
– Remove all the upholstery retaining clips -arrow A- on both
sides.
– Roll up the cover on the sides.

– Remove all the upholstery retaining clips - 3 - on the front side.


Installing
– Attach the cover - 1 - with new upholstery retaining clips - 3 -
to the upholstery - 2 - using the upholstery clip pliers - V.A.G
1634- .
Note
On vehicles with armrest, replace the upholstery retaining clips in the area of the armrest cutout -arrows-.


Skoda Rapid Body Work Eng

Uploaded by

Copyright:

Available Formats

Skoda Rapid Body Work Eng

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Skoda Rapid Body Work Eng

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.6 Removing and installing cap (without lock cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

68 - Interior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

1.2 Removing and installing the interior rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

69 - Passenger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

70 - Trim, insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

2 Door and side trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

72 - Seat frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

74 - Seat - padding, covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

1.2 Lock carrier with components parts

1 - Lock carrier with compo‐

1.3 Service position

2 Rep. gr.50 - Body - front

– Removing front bumper ⇒ “1.1.2 Removing”, page 132 .

– Install screws -2- and -3-.

Hoses and lines must not be pinched.

1.4 Removing and installing lock carrier with

4 Rep. gr.50 - Body - front

– Bring to service position ⇒ “1.3 Service position ”, page 2 .

If the cables of the air-conditioning system and/or the coolant

– Position the lock carrier - 1 - on the frame side rails - 2 -.

6 Rep. gr.50 - Body - front

1.5 Front wing

1.5.1 Summary of components

1.5.2 Removing front wing

– Remove front wheelhouse liner

8 Rep. gr.50 - Body - front

Carry out the following tasks

1.5.3 Installing the front wing

Carry out the following tasks

Install the wing -1- free of stress.

10 Rep. gr.50 - Body - front

1.6 Removing and installing the wing support

1.7 Bulkhead plenum chamber

1.7.1 Summary of components

1 - Bulkhead plenum chamber

– Remove the plenum

– Remove engine air duct

– Remove engine control

– Remove noise insula‐

– Unscrew screws -2-.

– Remove the bulkhead

– The installation occurs

Ensure that the seal is correctly

12 Rep. gr.50 - Body - front

1.8 Plenum chamber cover

1.8.1 Summary of components

– Remove wiper arms ⇒ Electrical System; Rep. gr. 92 .

14 Rep. gr.50 - Body - front

Carry out the following tasks

1.9 Noise insulation

1.9.1 Summary of components

– Remove the screws -2-

16 Rep. gr.50 - Body - front