Volkswagen Passat

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Body Exterior, Interior

01 - On Board Diagnostic (OBD) Airbag System, On Board Diagnostic (OBD), vehicles up to 09.94 Function Test requirements Scan Tool VAG1551, connecting and selecting function Diagnostic Trouble Code (DTC) Memory, checking Diagnostic Trouble Code (DTC) table Diagnostic Trouble Code (DTC) Memory, erasing, ending output Airbag system, On Board Diagnostic (OBD), vehicles from 10.94 Special tools Function Scan Tool VAG1551, connecting and selecting function Diagnostic Trouble Code (DTC) Memory, checking Diagnostic Trouble Code (DTC) table Diagnostic Trouble Code (DTC) Memory, erasing, ending output Airbag Control Module, coding with VAG1551 Scan Tool Measuring value block, reading Test box VAS5056

50 - Body - Front Body, front Lock carrier, removing and installing Front fender, removing and installing

55 - Hood, Lids Hood Hood lock cable, removing and installing Rear lid Rear lid lock, removing and installing (Sedan) Rear lid lock, removing and installing (Wagon) Lock cylinder, removing and installing Gas strut, removing Gas strut, emptying Rear lid springs, removing and installing Tailgate, adjusting (Wagon) Rear lid, adjusting (Sedan)

57 - Front doors, Central locking system Front door assembly Front door, servicing Front door assembly (with power window) Door, removing and installing Power window regulators, removing and installing Window glass, removing Window glass, installing on window regulator Outer window channel, removing Outer window channel, installing Lift channel, installing on door window glass Door inner seal, removing Power window regulators, removing and installing Power window regulators, repairing Door handle assembly (central locking system) Door handle, removing and installing Inner release handle, removing Common key locking, maintaining Door lock assembly Door lock assembly (with free-play adjustment), removing and installing Central locking, repairing (Sedan) Central locking, repairing (Wagon) Bi-pressure pump, installing (Sedan) Fuel tank flap activator, removing and installing Front door activator, removing and installing Rear door activator, removing and installing Central locking system, functional check Anti-theft function, checking

58 - Rear doors Rear door assembly Door, repairing Door, removing and installing Window regulator, removing and installing Door window glass, removing and installing Door window glass, installing Outer window channel, removing Outer window channel, installing Lift channel, installing on window glass Rear window regulator, servicing Side reinforcement, removing and installing Door lock assembly Door handle, removing and installing Door lock, removing and installing

Inner release handle, removing Door inner seal, removing

60 - Sunroof Sliding/tilting roof Special tools and equipment Sliding/tilting roof, component overview Sliding/tilting roof panel, removing Sliding/tilting roof panel, installing Parallel alignment, checking and adjusting Flap headliner, removing Panel for sliding/tilting roof, adjusting height Cable drive, checking 0-position Sliding/tilting roof assembly, removing Water drain hoses, cleaning Sliding/tilting roof with glass panel Assembly overview Sliding/tilting roof glass panel, removing Panel seal, adjusting Glass panel for siding/tilting roof, installing Sliding headliner, removing Sliding headliner, installing Parallel alignment, checking Parallel alignment, adjusting Glass panel for sliding/tilting roof, adjusting height Cable drive, checking 0-position

63 - Bumpers Bumpers Front bumper, removing and installing Air intake grille, removing Front bumper, removing from side member Rear bumper, removing and installing

64 - Glass, Window regulators Flush-bonded windows Special tools Materials Windshield, removing and installing Windshield, removing Windshield, installing Rear Window, removing and installing (Sedan)

Broken rear window, removing Undamaged window, removing Rear window, installing Undamaged rear window, removing (Wagon) Broken rear window, removing Rear window, installing Undamaged rear window, preparing for installation New rear window, preparing for installation Body flange, preparing for window installation Rear window, installing Curing time Paint repair Excess adhesive sealing material, cleaning Bolted windows Side window, removing and installing (Sedan) Side window, removing and installing (Wagon)

66 - Exterior equipment Roof moldings Sedan Roof frame (Wagon) Roof railing, removing and installing Radiator grille, removing and installing Wheel housing liner Exterior mirror Special tools Exterior mirror, assembly overview Protective moldings

68 - Interior equipment Inside mirror Inside mirror, removing and installing Inside mirror, repairing using glass/metal adhesive Luggage compartment cover, removing and installing Luggage compartment cover, retrofitting

Screen separator wall, retrofitting Reinforcement plates and securing eyes, installing Openings for cover caps, cutting out Screen separator wall, installing

69 - Passenger protection - Airbags, Seat belts Safety restraint system Vehicles with emergency tensioning seat belt retractors Seatbelts Front seat belts with emergency tensioning seat belt retractors, removing and installing Belt retractor with tensioning unit, removing and installing Seat belt height adjuster, removing and installing Front belt anchor, removing Front belt latch, removing Rear belt retractor, removing and installing LATCH System "Lower Anchors and Tethers for CHildren", installing and retrofitting (Sedan) LATCH System "Lower Anchors and Tethers for CHildren", installing and retrofitting (Wagon) Front belt tensioning unit, deploying (disposal) Seat belts, inspecting Airbag Airbag system, components Safety precautions when working on the airbag system Airbag units, replacing after an accident. Driver's airbag unit, removing and installing Steering wheel, removing and installing Airbag Spiral Spring -F138-, removing and installing Passenger's side airbag unit, removing and installing Retaining frame, removing Airbag Control Module -J234-, removing and installing Airbag units, deploying (disposal)

70 - Interior trim Instrument panel, removing and installing Knee bar, removing Center console, removing and installing Parking brake lever grip and trim, removing. Center console extension, removing and installing Storage shelf, driver's side, removing and installing Storage shelf, passenger's side, removing

Glove box, removing Glove box lock Door trim Front door trim Front door trim, removing and installing Rear door trim Rear door trim, removing and installing Door moisture barrier, removing and installing Trim Upper A-pillar trim, removing and installing Lower A-pillar trim, removing and installing B-pillar trim, removing and installing Upper C-pillar trim, removing and installing Lower C-pillar trim, removing and installing Lower C-pillar upholstery, removing and installing D-pillar trim (Sedan), removing and installing D-pillar trim, removing and installing (Wagon) Rear shelf and belt retractor cover, removing and installing (Sedan) Belt guide, removing Front luggage compartment trim and belt retractor cover, removing and installing (Wagon) Rear luggage compartment trim, removing and installing (Wagon) Luggage compartment side trim, (Sedan) Rear lock carrier trim, removing (Sedan) Rear lock carrier trim, removing (Wagon) Tailgate trim, removing and installing (Wagon) Tailgate hinge cover cap, removing and installing (Wagon) Sill cover, removing and installing Headliner Molded headliner, removing and installing (Sedan) Molded headliner with sunroof, removing and installing (Sedan) Headliner, removing and installing (Wagon) Headliner with sunroof, removing and installing (Wagon) Roof dampening / reinforcement, removing and installing

72 - Seats - Frames Front seat Front seat, removing Seat and backrest frames, separating Seat frame (standard and sport seat) Seat frame with mechanical height adjustment Seat frame with mechanical height adjustment, disassembling and assembling

Seat frame with electrical height adjustment Seat frame with electrical height adjustment, disassembling and assembling Backrest frame Backrest frame, replacing Rear seats Rear seat and split backrest, removing

74 - Seats - Upholstery, Covers Seat upholstery Cover and padding for front seat, removing and installing Cushion cover and padding for front seat with height adjustment, removing and installing Backrest cover and padding, removing and installing Rear seat cover and padding, removing and installing Backrest (split) covers and padding, removing and installing Backrest lock, removing and installing Heater element for seat, installing Center armrest, removing Upholstery clips, removing and installing

Airbag System, On Board Diagnostic (OBD), vehicles up to 09.94

Page 1 of 16 01-1

Airbag System, On Board Diagnostic (OBD), vehicles up to 09.94 Function The Airbag Control Module -J234- is located behind the console on the center tunnel. It is equipped with a Diagnostic Trouble Code (DTC) Memory. The Data Link Connectors (DLCs) are located to the right of the ignition switch. The Airbag Control Module -J234- detects malfunctions in the airbag system and stores them in a permanent memory. After the ignition is switched on, the Airbag Malfunction Indicator Lamp (MIL) -K75- comes on for about 3 seconds and then goes out again. If the MIL -K75- does not go out again, there is no voltage supply to the Airbag Control Module J234-. Correcting the malfunction Page 01-8 . If a malfunction exists, the MIL -K75- comes on again. To begin, start OBD and retrieve the stored information with the VAG1551 Scan Tool. The information displayed refers to a DTC table that lists possible causes and suggest repair measures.

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Test requirements All fuses OK according to wiring diagram Battery positive voltage (B+) OK (at least 10.5 V).

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Scan Tool VAG1551, connecting and selecting function Notes: The airbag system is switched off during the On Board Diagnostic. The DTC Memory can only be erased after repairs have been completed and the DTC Memory has been interrogated. Connect Scan Tool VAG1551 with adapter cable VAG1551/3 with ignition off to the Data Link Connectors (DLC) as follows: - Remove cover for DLCs located to the right of ignition switch.

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- With ignition switched off, connect Scan Tool VAG1551 with adapter cable VAG1551/3.

Indicated in display VAG1551 -D/7.0- 1.01.1997

The current software version is displayed briefly. Notes: If nothing is displayed, check voltage supply for VAG1551 according to wiring diagram. Electrical Wiring Diagrams, Troubleshooting and Component Locations You can print out additional operating information by pressing the HELP button of the VAG1551. The button is used for advancing the program sequence. Use the PRINT button to switch on the printer (control light in the button lights up).

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- Switch ignition on. - Press button -1- for "Rapid data transfer" mode. VAGOn Board Diagnostic

HELP

Indicated in display

1-Rapid data transfer*

* displayed alternately

2-Blink code *

Rapid data transfer

HELP

Indicated in display

Enter address word XX

- Press buttons -1- and -5- to select address word 15 for "Airbag". Rapid data transfer

Q

Indicated in display

15 Airbag

- Press -Q- button to confirm entry. Now a display like this appears for example: 357 959 656

AIRBAG IS 55

The Airbag Control module -J234- identification number is displayed.

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Notes: Rapid data transfer

HELP

If one of the following messages appears in the display the possible causes of the malfunction can be printed out with the HELP button.

HELP

Ignition must be switched on.

Control module does not answer!

Rapid data transfer K wire not switching to positive!

Rapid data transfer

Malfunctions have occurred at the start of or during the program. (external malfunctions?).

No signal from control module

Rapid data transfer

Check diagnostic harness, voltage supply and ground connections.

Fault in communication build -up

- After correcting possible causes of malfunction, again enter address word 15 for "Airbag" and confirm with -Q- button. Indicated in display after entering address word 15.

Rapid data transfer Tester sends address word 15

And then the following appears in the display: 357 959 656

AIRBAG IS 55

The Airbag Control module -J234- identification number is displayed. - Press

Rapid data transfer Select function XX

HELP

button.

Indicated in display (function selection, i.e. 02 Interrogate DTC Memory):

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Note: After pressing the HELP button, a list of possible functions is printed out. List of functions

page

01 - Control module version

Page 01-3

02 - Checking DTC Memory

Page 01-8

05 - Erasing DTC Memory

Page 01-15

06 - Ending output

Page 01-15

Only functions listed can be used at present for OBD. After pressing the button the VAG1551 program returns to the initial position.

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Diagnostic Trouble Code (DTC) Memory, checking Rapid data transfer

HELP

Indicated in display

Select function XX

- Press buttons -0- and -2- to select function 02 "Interrogate DTC Memory". Rapid data transfer

Q

Indicated in display

02 - Interrogate DTC Memory

- Press -Q- button to confirm entry.

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The number of stored DTCs or "No DTC recognized" appears on the display.

X DTC recognized!

No DTC recognized!

- Press

button.

The stored DTCs are displayed and printed out one after the other. - With the DTC printout go to the DTC table on Page 01-11 . After you press the button, the program moves to the initial position. Rapid data transfer

HELP

Indicated in display

Select function XX

- Ending output (function 06)

Page 01-15 .

- Switch off ignition and disconnect Data Link Connectors (DLC). Note: If a DTC was recognized: 1 . Correct malfunction 2 . Erase DTC memory (function 05) 3 . Again check DTC memory (function 02)

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Diagnostic Trouble Code (DTC) table Notes: Following are all malfunctions that are recognized by the Airbag Control Module -J234and which are printed out by the Scan Tool VAG1551 as a 5-digit DTC. DTCs and blink codes appear in the "Rapid data transfer" mode only in the printout. Example: DTC

Blink code

5-digit

4-digit

00277

1221

The malfunction type may also be listed in the DTC table. Before replacing any components suggested to be faulty, be sure to first check all wiring and ground connections according to the applicable wiring diagram. After you finish the repair, always interrogate and erase the DTC memory using Scan Tool VAG1551.

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Diagnostic Trouble Code (DTC) table VAG1551 printout

Possible cause

Corrective action

00000 4444 No DTC recognized

If "No DTC recognized" is displayed after a repair, the OBD is finished.

00532 2234 Voltage supply (B+) Signal too large

Generator faulty

- Check Generator. Electrical Wiring Diagrams, Troubleshooting and Component Locations

Control module faulty

- Replace control module if necessary

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VAG1551 printout

Possible cause

Corrective action

Wiring or connectors to airbag Control Module -J234-

- Check wiring and connectors to Airbag Control Module according to wiring diagram.

Battery discharged or faulty

- Charge battery or replace.

Airbag Igniter, driver's side -N95-

Wiring or connectors faulty

- Check wiring and connectors according to wiring diagram.

Resistance too high

Airbag Spiral Spring -F138faulty

- Replace Airbag Spiral Spring if necessary

Driver's Side Airbag Igniter N95- faulty

- Replace driver's side airbag unit if necessary

Control module faulty

- Replace control module

00532 2234 Supply voltage (B+) Signal too small

00588

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VAG1551 printout

Possible cause

Corrective action

Passenger's side Airbag Igniter 1 -N131-

Faulty wiring or connectors

- Check wiring and connectors according to wiring diagram

Resistance too high

Passenger'side Airbag Igniter N131- faulty

- Replace Passenger'side Airbag Igniter if necessary

Control module faulty

- Replace control module if necessary

Faulty wiring or connectors to airbag units

- Check wiring and connectors according to wiring diagram

Control module faulty

- Replace control module if necessary

00589

00651 Wiring to igniter

Short circuit to B+ Short circuit to Ground

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VAG1551 printout

Possible cause

Corrective action

65535 1111 Control module faulty Control module faulty Replace control module if necessary

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Diagnostic Trouble Code (DTC) Memory, erasing, ending output Requirements: Malfunction was repaired DTC memory was checked again DTC Memory, erasing - Press Rapid data transfer

HELP

button.

Indicated in display

Select function XX

- Press buttons -0- and -5- ("Erase DTC Memory" is entered with 05) Rapid data transfer

Q

Indicated in display

05 - Erase DTC memory

- Press -Q- button to confirm entry. Indicated in display

Rapid data transfer DTC memory erased!

- Press Rapid data transfer

HELP

button.

Indicated in display (release for function selection):

Select function XX

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Note: If this is indicated in the display, the procedure was faulty.

CAUTION DTC memory was not interogated

Follow procedure: First interrogate DTC memory, then erase it. End output - Press buttons -0- and -6- to end output. Rapid data transfer

HELP

Indicated in display (release for function selection):

06 - End output

- Press -Q- button to confirm entry.. Rapid data transfer

HELP

Indicated in display

Select function XX

- Switch ignition off. - Disconnect Scan Tool VAG1551. - Switch ignition on. Airbag MIL -K75- must light up for about 3 seconds and then go out.

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94 Special tools Special tools and equipment: VAG1551/3 Adapter cable VAG1551 Scan Tool VAS5056 Test box

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Function The Airbag Control Module -J234- is located behind the console on the center tunnel. It is equipped with a Diagnostic Trouble Code (DTC) Memory. The Data Link Connectors (DLCs) are located to the right of the ignition switch. The Airbag Control Module -J234- detects malfunctions in the airbag system and stores them in a permanent memory. After the ignition is switched on, the Airbag Malfunction Indicator Lamp (MIL) -K75- comes on for about 4 seconds and then goes out again. If the MIL continues to blink for additional 12 seconds it signals that the passenger airbag is disconnected. If the MIL -K75- does not go out after about 4 seconds, the supply voltage (B+) for the Airbag Control Module -J234- is faulty. CheckDTC memory Page 01-25 . If the MIL -K75- comes on again then a malfunction exists. CheckDTC memory 01-25 .

Page

If the MIL continues to blink, replace Control Module -J234-.

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Before beginning to troubleshoot, start the On Board Diagnostic (OBD) using VAG1551 Scan Tool. The information displayed is used to refer to a DTC table that lists possible causes and suggest repair measures. CAUTION! Only check wiring visually. Do not make electrical open circuit checks or checks of the ignition system. Check wiring routing only with the ignition switched off.

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Scan Tool VAG1551, connecting and selecting function Test requirements for OBD All fuses OK according to wiring diagram. Battery positive voltage (B+) OK (at least 10.5 V). - Remove cover for Data Link Connectors (DLC) to right of ignition switch. - Switch ignition off. - Connect Scan Tool VAG1551 using adapter cable VAG1551/3.

Indicated in display VAG1551 -D/7.0- 1.01.1997

The current software version is briefly displayed.

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VAGOn Board Diagnostic

HELP

Indicated in display

1-Rapid data transfer* 2-Blink code display*

* Displayed alternately Notes: If nothing is displayed, check voltage supply for VAG1551 according to wiring diagram. Electrical Wiring Diagrams, Troubleshooting and Component Locations. You can print out additional operating information by pressing the HELP button of the VAG1551. The button is used for advancing the program sequence. Use the PRINT button to switch on the printer (control light in the button lights up).

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Control module version, checking - Switch ignition on. - Press button -1- for "Rapid data transfer" mode. Rapid data transfer

HELP

Indicated in display

Enter address word XX

- Press buttons -1- and -5- to select address word 15 for airbag system. Rapid data transfer

Q

Indicated in display

15 - Airbag

- Press -Q- button to confirm entry. 6N0 909 603 H AIRBAG VW 2 V00 Coding 00072

WSC12345

Indicated in display (current control module version see Parts catalogue): Upper line:

Control module Part No. System description (AIRBAG VW2) Version number

Lower line:

Code number Dealer number1)

1)-

is automatically stored in the control module when entering current system. - Press

button.

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Rapid data transfer

HELP

Indicated in display

Select function XX

Notes: Rapid data transfer

HELP

If one of the following malfunction messages appear in the display, the possible causes of the faults can be printed out with the HELP button.

HELP

(Ignition must be switched on!)

Control module does not answer!

Rapid data transfer K-wire not switching to positive!

Rapid data transfer No signal from control module!

Rapid data transfer

Malfunctions have occurred at the start of or during the program (external malfunction sources?). Check diagnostic wiring and ground connections.

Fault in communication build -up

- After correcting possible causes of malfunction, again enter address word 15 for "Airbag" and confirm by pressing -Q- button. Indicated in display after entering address word 15.

Rapid data transfer Tester sends address word 15

and then this will appear in the display: 6N0 909 603 H AIRBAG VW 2 V00 Coding 00072

WSC12345

Indicated in display (for current control module versions see parts catalog)

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List of functions

page

01 - Control module version

Page 01-22

02 - Checking DTC Memory

Page 01-25

05 - Erase DTC Memory

Page 01-31

06 - Ending output

Page 01-32

07 - Coding control module

Page 01-33

08 - Reading measuring value block

Page 01-36

Notes: After pressing the HELP button, a list of possible functions is printed out.. Do not select other functions that may be printed out when pressing the HELP button. After ending the functions, the Scan Tool VAG1551 will return to the following starting position:

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Diagnostic Trouble Code (DTC) Memory, checking Rapid data transfer

HELP

Indicated in display

Select function XX

- Press buttons -0- and -2- to select function 02 "Interrogate DTC Memory". Rapid data transfer

Q

Indicated in display

02 - Interrogate DTC Memory

- Press PRINT button. - Press -Q- button to confirm entry. The display shows the number of stored malfunctions.

X DTC recognized!

The stored DTCs are printed out one after the other. - With the printout go to the DTC table and correct malfunctions If "No DTC recognized" is shown, the program starts at the beginning after pressing the button.

No DTC recognized!

Rapid data transfer

HELP

Indicated in display

Select function XX

If something else is shown in the display:

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Operating instruction of Scan Tool - Ending output (function 06)

Page 01-32 .

- Switch ignition off and disconnect Data Link Connector (DLC). Note: If a malfunction was recognized: 1 . Repair malfunction 2 . Erase DTC Memory (function 05)

3

. Again check DTC memory (function 02)

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Diagnostic Trouble Code (DTC) table Notes: All possible DTCs, which can be recognized by the Airbag Control Module -J234- and printed out by the Scan Tool VAG1551 are listed below as a 5-digit DTC. The DTC code is only shown in the print-out. Before replacing components listed as faulty, always first check wiring and ground connections according to the wiring diagram. Check all connectors at the relay panel for good connection. After completed repair, always interrogate DTC memory and then erase memory using Scan Tool VAG1551. The DTC table may contain the fault category. VAG1551 printout

Possible cause

Corrective action

00000 No malfunction recognized

If "No malfunction recognized" is displayed, the OBD is finished.

00532 Supply voltage (B+) Signal too large

Generator faulty

- Check Generator Electrical Wiring Diagrams, Troubleshooting and Component Locations

Signal too small

Wiring or connector to Airbag Control Module -J234-

- Check wiring and connector to control module according to wiring diagram

Battery discharged or faulty

- Charge battery or replace

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VAG1551 printout

Possible cause

Corrective action

Faulty wiring or connectors

- Replace or repair faulty wiring or connectors

Driver's side Airbag Igniter -N95faulty

- Replace Driver's side Airbag Igniter N95-

Airbag Spiral Spring -F138faulty

- Replace Airbag Spiral Spring -F138-

00588 Driver's side Airbag Igniter N95Resistance value too high Resistance value too low Short circuit to positive Short circuit to ground

- Read measuring value block Page 01-36

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 13 of 28 01-29

VAG1551 printout

Possible cause

Corrective action

Faulty wiring or connectors

- Replace or repair faulty wiring or connectors

Passenger's side Airbag Igniter N131- faulty

- Replace Passenger's side Airbag Igniter -N131-

00589 Passenger's side Airbag Igniter -N131Resistance value too high Resistance value too small Short circuit to positive Short circuit to ground

- Read measuring value block Page 01-36 00594 Igniter circuit for airbag Short circuit

Faulty wiring or connectors to airbag units

- Read measuring value block Page 01-36

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 14 of 28 01-30

VAG1551 printout

Possible cause

Corrective action

00595 Crash data stored Short circuit

- Replace control module Short circuit in igniter circuits

- Replace control module - Replace or repair faulty wiring or connectors - Replace airbag unit and all faulty components

012801) Driver's side airbag is disconnected

Driver's side airbag does not function

Control module was adapted

65535 Control module faulty 1)

Control module faulty

Replace control module

DTC is stored in memory only during activated adaptation.

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 15 of 28 01-31

Diagnostic Trouble Code (DTC) Memory, erasing, ending output Requirements: Malfunction was repaired DTC memory was checked again DTC Memory, erasing Rapid data transfer

HELP

Indicated in display

Select function XX

- Press buttons -0- and -5- to select function 05 "Erase DTC Memory". Rapid data transfer

Q

Indicated in display

05 - Erase DTC Memory

- Press -Q- button to confirm entry.. Indicated in display

Rapid data transfer DTC memory was not erased!

- Press Rapid data transfer

HELP

button.

Indicated in display

Select function XX

Note: CAUTION! DTC memory was not interrogated

If this is shown in the display, the program sequence is not correct. Always follow exact checking sequence: first interrogate DTC memory, then erase DTC memory.

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 16 of 28 01-32

DTC Memory, ending output - Press buttons -0- and -6- to end output. Rapid data transfer

Q

Indicated in display

06 - Ending output

- Press -Q- button to confirm entry. Rapid data transfer

HELP

Indicated in display

Enter address word XX

- Switch ignition off. - Disconnect Data Link Connectors (DLC) to Scan Tool VAG1551.

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 17 of 28 01-33

Airbag Control Module, coding with VAG1551 Scan Tool Coding is only possible when a new control module is used. - Connect VAG1551 Scan Tool. - Switch ignition on. - Press button -1- for "Rapid data transfer" mode. Rapid data transfer

HELP

Indicated in display

Enter address word XX

- Press buttons -1- and -5- to select address word 15 "Airbag". Rapid data transfer

Q

Indicated in display

15 - Airbag

- Press -Q- button to confirm entry. The airbag MIL -K75- continues to light up. 6N0 909 603 H AIRBAG VW 2 V00 Coding 00072

WSC12345

Indicated in display (for current control module versions see parts catalog). - Press

Rapid data transfer

HELP

button.

Indicated in display

Select function XX

- Press buttons -0- and -7- to select function 07 "Code control module. Rapid data transfer

Q

Indicated in display

07 - Code control module

- Press -Q- button to confirm entry.

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 18 of 28 01-34

Control module coding

Q

Indicated in display

Enter code number XXXXX (0 --32000)

- Enter code number according to table: Vehicle options

Part number

Index

Code number

Driver's side airbag only

6N0 909 603

J

00074

Driver's and passenger's airbags

6N0 909 603

H

00072

Airbag with knee bar

6N0 909 603

G

00071

- Press -Q- button to confirm entry. 6N0 909 603 H AIRBAG VW2 Coding 00072

V00 WSC 12345

Indicated in display is the control module identification number with the appropriate letter index, the code number and the dealer code. The coding is completed if the display contents is shown. If the entered code number was not accepted by the control module, the following display appears:

Error

Indicated in display

Coding XXXXX not accepted

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 19 of 28 01-35

In this case the control module was not programmed with the necessary data; coding is then not possible. The airbag MIL -K75- stays on. Check whether the correct control module for the car was installed (compare part number and letter index) or whether an incorrect code number was entered. End function: - Press Rapid data transfer

HELP

button.

Indicated in display

Select function XX

- Press buttons -0- and -6- to end output. - Press -Q- button to confirm entry. Rapid data transfer

Q

Indicated in display

06 - Ending output

The airbag MIL -K75- must go out after about 4 seconds.

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 20 of 28 01-36

Measuring value block, reading CAUTION! Only inspect wiring visually. Do not perform electrical continuity testing or measurements in the airbag ignition circuits. Only check wiring with the ignition off. Rapid data transfer

HELP

Indicated in display

Select function XX

- Press buttons -0- and -8- to select function 08 "Read measuring value block". Rapid data transfer

Q

Indicated in display

08 - Read measuring value block

- Press -Q- button to confirm entry. Read measuring value block

HELP

Indicated in display

Enter display group number XX

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 21 of 28 01-37

- Select display group number and press -Qbutton to confirm entry. Read measuring value block

1

Indicated in display

1234

Explanations for the display contents is listed in the display group overview Page 01-39 . If "correct" is shown in all display fields: - Press Rapid data transfer

HELP

button.

Indicated in display

Select function XX

Note: After finishing with function "Read measuring value block", go to function "Interrogate DTC Memory" Page 01-25 .

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 22 of 28 01-38

Display group 001 Display group 001 Read measuring value block 1

Indicated on display

xxxx

xxx

xxx

xxxx

1

2

3

4

Display fields

Specified value

Driver's side belt tensioner

Not used for troubleshooting

Driver's side belt tensioner Driver's side Airbag Igniter Driver's side Airbag Igniter

Evaluation

Not used for troubleshooting correct

Page 01-39

correct

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 23 of 28 01-39

Evaluation of display group number 001 Correction

Display field

Designation

Display contents

1

Driver's side Airbag Igniter -N95-

correct

- No malfunction found

Trig. GND

- Check wiring visually

POS

- Check connectors of applicable circuit for correct seating, at the same time watch display. If display changes to "correct", erase DTC memory - Disconnect connector for igniter for airbag unit Display changes to "too large"

too small

- Replace airbag unit Display remains on "too small" - Disconnect connector for connector for Airbag Spiral Spring Display changes to "too large" - Replace Airbag Spiral Spring Display remains on "too small" - Replace wiring harness Continue next page

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 24 of 28 01-40

Displayfield Designation 1

Display contents too large

Correction - Remove connector from igniter for airbag unit - Connect connector for airbag igniter to inert igniter of VAS5056 Page 01-43 . Display changes to "correct" - Replace airbag unit Display remains on "too large" - Remove connector for airbag spiral spring - Connect test box VAS5056 instead of airbag spiral spring to driver's side harness Page 01-43 . Display changes to "correct" - Replace Airbag Spiral Spring -F138Display remains on "too large" - Press button of VAS5056 Display remains on "too large" - Replace wiring harness Continue next page

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 25 of 28 01-41

Displayfield

Designation

Display contents

2

Passenger's side Airbag Igniter -N131-

correct Trig. GND POS too small

Correction No malfunction found - Visually check wiring - Check connectors of applicable circuit for correct seating, at the same time watch display - If display changes to "correct", erase DTC Memory - Disconnect connector between adapter wire and airbag unit Display changes to "too large" - Replace airbag unit Display remains on "too small" - Replace wiring harness - Connect test box VAS5056 to passenger's side harness Page 01-43 .

too large

- Press button of VAS5056 Display changes to "too small" - Replace airbag unit - Display remains on "too large" - Replace wiring harness

3

Not used for troubleshooting

4

Not used for troubleshooting

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 26 of 28 01-42

Display group 003 Read measuring value block 3

Indicated on display

xxxx

xxx

xxx

xxxx

1

2

3

4

Specified value

Display fields Driver's side belt buckle switch

Not used for troubleshooting

Driver's side belt buckle switch

Not used for troubleshooting

Passenger's side seat occupant recognition Supply voltage (B+)

Evaluation

Not used for troubleshooting correct

Page 01-42

Evaluation of display group number 003 Display field 1

Designation Supply voltage (B+)

Display contents correct too small too large

2+3+4

Correction - Supply voltage (B+) min. 10.5 Volt - Check Generator Electrical Wiring Diagrams, Troubleshooting, Component Locations - Check wiring visually

Not used for troubleshooting

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 27 of 28 01-43

Test box VAS5056 With test box VAS5056 it is possible to test the individual airbag system components to determine which component is actually malfunctioning. Note Observe safety measures when working on airbag system Page 69-23 . Test box VAS5056, connecting with driver's side airbag system components Remove lower steering column switch trim - Connect igniter connector to inert igniter -1- and disconnect harness to airbag spiral spring. Connect yellow dual connector -3- of VAS5056/1 with airbag harness. 1 - Connector on inert igniter 2 - VAS5056 button 3 - Connector for spiral spring/return spring with slip ring

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Airbag system, On Board Diagnostic (OBD), vehicles from 10.94

Page 28 of 28 01-44

Test box VAS5056, connecting with passenger's side airbag system components - Remove storage shelf on passenger's side Page 70-11 - Disconnect harness connector to airbag unit. Connect yellow dual connector -2- of VAS5056/1 with passenger's side airbag harness 1 - VAS5056 button 2 - Connector for passenger's side airbag harness 3 - Connector (not used) 4 - Connector (not used)

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Body, front

Page 1 of 4 50-1

Body, front 1 - Self-locking bolt 12 Nm (9 ft lb) When re-using: Clean bolt thread with wire brush and nut thread with thread tap. Coat bolt with locking fluid D 185 400 A 2. 2 - Lock 3 - Clip 4 - Self-tapping screw 5 Nm (44 in. lb) 5 - Lock carrier Removing and installing Page 50-2

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12/7/2004

Body, front

Page 2 of 4 50-2

Lock carrier, removing and installing Removing - Remove front bumper

Page 63-1

- Remove radiator grille and trim

Page 66-9

- Remove lock -1- and free Bowden cable. - Disconnect connector for headlight and front turn signal light. - Loosen clip holding hydraulic fluid reservoir -2- . - Remove A/C refrigerant hose from retaining clip. - Remove bolts -3- .

- Remove bolts -1-.

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Body, front

Page 3 of 4 50-3

Front fender, removing and installing Removing - Remove front bumper, guide part, wheel hose liner, radiator grille and trim Page 63-1 and Page 66-9 . - Press bumper cover down (with rubber wedges or similar) in area of outer bolts and remove bolts. To avoid scratches, tape off areas with masking tape.

- Remove bolts (arrows) from wheel housing.

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Body, front

Page 4 of 4 50-4

- Remove bolts (arrows). Installing Observe corrosion protection measures as specified in the Repair Manual, Body Collision Repair. - Before installing fender, install zinc packing AKL 381 035 50 to mounting points in contact area of wheel house A-pillar. - Adjust gaps by moving fender. Gap sizes: a

5 1 mm, b

5 1 mm.

Note: Do not pinch water drain hose for power window.

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Hood

Page 1 of 2 55-1

Hood Hood lock cable, removing and installing 1 - Release lever Cable attached. 2 - Self-tapping screw 3 - Grommet 4 - Clip 5 - Guide 6 - Cable clip 7 - Bolt, self-locking 12 Nm (9 ft lb) When re-using: clean bolt threads with wire brush and nut threads with thread tap. Coat bolt with locking fluid D 185 400 A 2.

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Hood

Page 2 of 2 55-2

8 - Lock Cable attached. 9 - Cable Replacing: Remove release lever and lock, remove cable. Attach string or similar, about 1000 mm (1 yard) long to nipple of cable (release lever) and pull cable out from engine compartment side. Use string or similar for pulling cable in.

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Rear lid

Page 1 of 13 55-3

Rear lid Rear lid lock, removing and installing (Sedan) 1 - Lock cylinder housing Remove rear trim panel before removing lock cylinder housing. - Remove screw - 10 , unclip hinge sleeve - 3 - from relay lever - 11 -. For central locking system also unclip operating rod. Remove lock cylinder Page 55-8 2 - Rod clip

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Rear lid

Page 2 of 13 55-4

3 - Connector sleeve When installing pull rod, press relay lever 11 - against lock cylinder and clip connector sleeve together. 4 - Pull rod Press relay lever - 11 against stop and insert pull rod stress-free. 5 - Connector for luggage compartment light switch 6 - Bolt 7 Nm (62 in. lb) 7 - Locking plate 8 - Bolt 7 Nm (62 in. lb) 9 - Lock 10 - Screw 7 Nm (62 in. lb) 11 - Relay lever

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Rear lid

Page 3 of 13 55-5

Rear lid lock, removing and installing (Wagon) 1 - Lock cylinder housing Remove rear trim panel before removing lock cylinder housing. - Remove screws - 10 -, unclip connector sleeve - 3 - from relay lever - 11 -. For central locking system also unclip operating rod. Remove lock cylinder Page 55-8 2 - Rod clip

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Rear lid

Page 4 of 13 55-6

3 - Connector sleeve When installing pull rod, press relay lever against lock cylinder and clip connector sleeve together. 4 - Pull rod Press relay lever - 11 against stop and insert pull rod stress-free. 5 - Connector for rear compartment light switch 6 - Lock Before installing lock, attach connector and clip pull rod in ( see item - 4 -). 7 - Bolts 23 Nm (17 ft lb) 8 - Locking plate

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Rear lid

Page 5 of 13 55-7

9 - Bolt 23 Nm (17 ft lb) 10 - Screw 7 Nm (62 in. lb) 11 - Relay lever 6 Nm (53 in. lb)

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Rear lid

Page 6 of 13 55-8

Lock cylinder, removing and installing 1 - Lock cylinder housing Removing Page 553 and Page 55-5 2 - Spring for push-button 3 - Push-button 4 - Sealing ring 5 - Lock cylinder Remove lock cylinder only with key inserted. 6 - Sealing ring 7 - Guide cylinder

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Rear lid

Page 7 of 13 55-9

8 - Lock cylinder, lower part Removing: press out circlip - 10 -, press relay lever - 9 outward 9 - Relay lever 10 - Circlip 11 - Joint bushing

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Rear lid

Page 8 of 13 55-10

Gas strut, removing - Support tailgate. - Remove retaining clip -1-. - Lift retainer -2- with screwdriver and pull gas strut from ball joint. Note: If you are reusing the gas strut, do not take out retainer -2- completely or the retainer will be damaged.. 3 - Mounting bracket 4 - Bolt, 7 Nm (62 in. lb) 5 - Sealing washer 6 - Ball joint, 20 Nm (15 ft lb)

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Rear lid

Page 9 of 13 55-11

Gas strut, emptying - Clamp gas strut in vice in area x

50 mm.

WARNING! Only clamp gas-filled strut in designated area. Wear protective goggles when sawing gas strut. - Saw through cylinder of gas strut within first third of total length , using piston rod end of cylinder as reference point. Notes: Cover area of saw cut with a rag. Dispose of oil and rag properly..

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Rear lid

Page 10 of 13 55-12

Rear lid springs, removing and installing - Open rear lid and secure with support. - Move jaws of special tool 3072 as closely together as possible by turning spindle counterclockwise. - Align tool 3072 over complete length of spring (spindle hex points toward luggage compartment opening) and press jaws between spring coils. - Install retainers -1- over spring and tighten wing nuts -2- to stop. - Expand spring with special tool 3072 by turning spindle clockwise until spring can be unhooked. Installation hints: - Install spring to hinge pin -arrow-. - Hook spring into center hole -1- of body plate.

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Rear lid

Page 11 of 13 55-13

Tailgate, adjusting (Wagon) 1 - Threaded sleeve (left-hand thread) 2 - Spacer web 3 - Spreader pins with disassembling slot 4 - Detent lugs for basic setting 5 - Recess for detent lugs 6 - Detent slide 7 - Clamping screw 8 - Rubber buffer - Pry out spreader pin with small screw driver and take out adjusting stop from tail gate. - Remove rubber buffer and unscrew clamping screw (socket head screw 3 mm) to edge of detent slot. - Adjust threaded sleeve -1- (left-hand thread) to clearance of a = 3 mm. Check clearance with hex socket wrench -9-. Reinstall rubber buffer.

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Rear lid

Page 12 of 13 55-14

Note: When new, set the adjustment stop to a clearance of 3 mm. The spacer web -2- rests against the threaded sleeve -1-. - Pull out detent slide and press in again as far enough until locking lugs -4- engage in recess -5-. Clearance between housing and rubber buffer b mm.

10

- Insert adjusting stop, press in spreader pins. - Close tailgate with light pressure. - Open tailgate again. - Tighten clamping screw -7- with 1 Nm (9 in. lb).

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Rear lid

Page 13 of 13 55-15

Rear lid, adjusting (Sedan) - Rear lid is guided by the slide plate -2- and the spacer buffer -1-. - Install stop buffer -4- and press in spreader pin -5-. - Lightly tighten bolt -6- and push slide piece -3- upward. - Close rear lid using light pressure until it aligns with side part. - Open rear lid and tighten bolt -6-.

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Front door assembly

Page 1 of 30 57-1

Front door assembly Front door, servicing Note: The door side reinforcement cannot be removed. 1 - Door hinge Bolted to door, inserted toward A-pillar and secured with grub screw. 2 - Trim plate 3 - Outer window channel Inserted into window frame. Cannot be removed without destroying it. Removing 13 Installing 14

Page 57Page 57-

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Front door assembly

Page 2 of 30 57-2

4 - Window glass Removing 11

Page 57-

Installing to window regulator Page 5712 Lift channel on glass, dimension Page 5715 5 - Door Removing and Installing Page 57-9 Adjust at hinge within oversized holes. 6 - Outer window slot seal Pushed onto flange. 7 - Inner window slot seal Pushed onto flange. 8 - Inner window channel Pushed onto flange.

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Front door assembly

Page 3 of 30 57-3

9 - Window channel, rear 10 - Seal Outer securing clip additionally bonded. 11 - Clip two-part 12 - Bolt 7 Nm (62 in. lb) 13 - Window regulator Removing and Installing Page 5710 Installing glass to window regulator Page 57-12 14 - Sleeve without ridge Before removing window regulator, remove sleeve. 15 - Door check strap boot 16 - Door check strap

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Front door assembly

Page 4 of 30 57-4

17 - Bolt 7 Nm (62 in. lb) 18 - Clip 19 - Locking nut 6.5 Nm (58 in. lb) 20 - Window channel, front Remove downward and toward inside of door. 21 - Bolt 55 Nm (41 ft lb) 22 - Door check strap cover Self-adhesive, glued to A-pillar. 23 - Multi-pin connector Separation point for all electrical and pneumatic connections. Remove coupling nut and pull off.

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12/7/2004

Front door assembly

Page 5 of 30 57-5

Front door assembly (with power window) Note: The door side reinforcement cannot be replaced 1 - Door hinge Bolted to door, inserted toward A-pillar and secured with grub screw. 2 - Cover 3 - Outer window channel Inserted into window frame Cannot be removed without destroying it. Removing 13 Installing 14

Page 57Page 57-

4 - Window glass Removing 11

Page 57-

Installing to window regulator Page 5712 Lift channel to glass, dimension Page 5715

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12/7/2004

Front door assembly

Page 6 of 30 57-6

5 - Door Removing and Installing Page 57-9 Adjust at hinge within oversized holes. 6 - Outer window slot seal Pushed onto flange. 7 - Inner window slot seal Pushed onto flange. 8 - Inner window channel Pushed onto flange. 9 - Rear window channel 10 - Bolt 7 Nm (62 in. lb) 11 - Clip two-part

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Front door assembly

Page 7 of 30 57-7

12 - Seal Outer securing clip additionally bonded. 13 - Window regulator Removing and Installing Page 5710 Installing window glass to window regulator Page 57-12 Removing and installing (electrical) Page 57-17 14 - Window regulator motor Removing and installing Page 5718 15 - Door check strap boot 16 - Door check strap 17 - Bolt 7 Nm (62 in. lb)

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Front door assembly

Page 8 of 30 57-8

18 - Clip 19 - Lock nut 6.5 Nm (58 in. lb) 20 - Front window channel Remove downward and toward inside of door. 21 - Bolt 55 Nm (41 ft lb) 22 - Door check strap cover Self-adhesive, stuck to A-pillar. 23 - Multi-pin connector Separation point for all electrical and pneumatic connections. Unscrew coupling nut and pull off.

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12/7/2004

Front door assembly

Page 9 of 30 57-9

Door, removing and installing For doors with central locking system and /or power windows: - Disconnect multi-pin connector -1- at A-pillar. - Remove nut -2- and remove pin. - Remove grub screw -arrow- from upper and lower hinges. - Lift door up and out of hinge brackets. Notes: Clean screw with wire brush and nut thread with thread tap. Coat screw with locking fluid D 185 400 A 2. Tighten nut -2- to 6.5 Nm (57 in. lb).

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Front door assembly

Page 10 of 30 57-10

Power window regulators, removing and installing - Unbolt window glass from window regulator. - Push window glass up and secure in position (i.e. with adhesive tape). - Pull off sleeve -1- from window regulator axis. - Remove window regulator. - Raise window regulator until retaining lugs disengage and remove regulator downward. Note: Window glass installing to window regulator 57-12 .

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Front door assembly

Page 11 of 30 57-11

Window glass, removing - Pull inner window glass forward and lift out of flange. - Lower window and unbolt window glass. - Tilt window glass forward and lift out of window slot.

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Front door assembly

Page 12 of 30 57-12

Window glass, installing on window regulator - Place window rail -1- onto channel -2- . - Bolt window glass to window regulator but do not tighten. - Raise window and then down again until bolts are visible through holes -3-. - Tighten bolt to 7 Nm (62 in. lb).

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Front door assembly

Page 13 of 30 57-13

Outer window channel, removing - Remove inner and outer triangular trim plates. - Pull outer window slot seal off flange. - Pull inner window channel off flange. - Starting at the rear upper corner, press out outer window channel off flange.

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Front door assembly

Page 14 of 30 57-14

Outer window channel, installing - Install channel into rear of window slot. - Press window channel down and starting at upper corner, press onto flange. Retaining lip -arrowmust engage fully.

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Front door assembly

Page 15 of 30 57-15

Lift channel, installing on door window glass - Press lift channel onto window glass, a mm.

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Front door assembly

Page 16 of 30 57-16

Door inner seal, removing - Remove inner trim

Page 70-34 .

Inner trim -1- holds inner door seal. Joint position -2- below sill panel trim, dimension a 520 20 mm.

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12/7/2004

Front door assembly

Page 17 of 30 57-17

Power window regulators, removing and installing - Remove window glass from window regulator. - Push window glass up and fasten in position with adhesive tape. - Remove connector from power window motor. - Unbolt window regulator. - Lift window regulator and disengage retaining lugs. Remove window regulator downward and out.

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Front door assembly

Page 18 of 30 57-18

Power window regulators, repairing - Power window regulator, removing 17 .

Page 57-

- Remove eccentric disc -1- by removing bolt from reverse side.

- Remove (Torx) screws for motor -arrows- and remove motor. Notes: Check function of regulator before installing it. Replacement of mechanical parts (linkage/cable) is done in the same manner.

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Front door assembly

Page 19 of 30 57-19

Door handle assembly (central locking system) 1 - Door handle with wiring for central locking Removing and installing Page 5721 Remove wiring from clip. 2 - Lock cylinder With seal Removing: - Insert key into lock cylinder. - Remove lock ring - 7 -with small screwdriver. - Remove eccentric 6 -, spring - 5 - and idler - 4 -. - Turn lock cylinder with inserted key 180 and pull out of door handle. Before installing, lubricate lock cylinder with G 000 400. Maintain common key locking Page 57-23

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Front door assembly

Page 20 of 30 57-20

3 - Microswitch Cannot be removed. 4 - Idler 5 - Spring 6 - Eccentric Insert with preassembled spring. 7 - Circlip

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Front door assembly

Page 21 of 30 57-21

Door handle, removing and installing Remove door trim panel, carefully pull off moisture barrier and disconnect harness connector. Note: Right screw -1- has left-hand thread and flat black finish. - Remove screw -1- (7 Nm (62 in. lb). - Push door handle in direction of arrow and pivot out of door. Notes: Check padding -2- and clip -3- for damage, replace if necessary. Observe routing of wiring in door interior and secure with clips.

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Front door assembly

Page 22 of 30 57-22

Inner release handle, removing - Press clip out of hole in door inner panel. - Press handle in forward direction out of mounting holes.

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Front door assembly

Page 23 of 30 57-23

Common key locking, maintaining Common key locking can be maintained in the vehicle by repositioning or inserting tumblers -5-. 1; 2; 3; 4 - possible tumbler sizes

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Front door assembly

Page 24 of 30 57-24

Door lock assembly 1 - Backing 2 - Door handle Removing and installing Page 5721 On right side with lefthand thread (screw has flat black finish. On vehicles with central locking remove front door interior trim first and disconnect harness connection. Servicing with central locking Page 57-19 3 - Lock cylinder Removing and installing Page 5719

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Front door assembly

Page 25 of 30 57-25

4 - Sealing ring 5 - Clip 6 - Connector for central locking. 7 - Backing 8 - Screw On the right side with left-hand thread (screw has flat black finish). 7 Nm (62 in. lb) 9 - Locking rod 10 - Locking knob Screwed on 11 - Connecting lever

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Front door assembly

Page 26 of 30 57-26

12 - Door lock with freeplay adjustment Removing and installing Page 5728 The door must be closed for removing and installing. 13 - Striker pin 50 Nm (37 ft lb) 14 - Dished spring washer Outer edge must face toward outside. 15 - Plastic washer 16 - Screw 20 Nm (15 ft lb) 17 - Seal Must be installed with matching door lock.

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Front door assembly

Page 27 of 30 57-27

18 - Pull rod Hook into interior release mechanism from bottom to top. 19 - Anti-theft protection 20 - Circlip 21 - Clip 22 - Eccentric 23 - Spring 24 - Inner door release handle Removing 22

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Front door assembly

Page 28 of 30 57-28

Door lock assembly (with free-play adjustment), removing and installing 1 - Door handle Removing and installing Page 5721 2 - Door lock with freeplay adjustment Removing and installing Page 5729 3 - Screw 20 Nm (15 ft lb) 4 - Cover 5 - Nut Free-play adjustment

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Front door assembly

Page 29 of 30 57-29

Removing Door window must be closed. - Unclip cover. - For removal and installation, operating lever must be locked with 3 mm diameter drift through hole (open door from inside)

- Remove screws -1-. - Pull away door lock slightly and lock operating lever with 3mm diameter drift through hole -2-. - Pull out door lock and unlock pull rod from interior door release handle.

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Front door assembly

Page 30 of 30 57-30

Installing - Loosen nut -3- with 5.5 mm wrench. Release lever releases tension. 1 - Assembly position - Install door lock. Free-play adjustment is accomplished between release lever and relay lever. 2 - Installation position - Tighten nut -3- , 2.4 Nm (left side: right-hand thread, right hand side: left-hand thread). - Make adjustment every time door handle or door lock is installed. Check for proper functioning after installation. - Install cover.

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Central locking, repairing (Sedan)

Page 1 of 14 57-31

Central locking, repairing (Sedan) 1 - Fuel tank flap activator Before removing, remove rear compartment trim up to wheel house. Removing and installing Page 5737 2 - Rear lid activator Remove screws for activator and and unclip connecting rod. 3 - T-connector Location: wheel house / backrest covered by rear compartment carpeting. 4 - Bi-pressure pump Remove rear compartment trim before removing. Installing 36

Page 57-

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Central locking, repairing (Sedan)

Page 2 of 14 57-32

5 - T-connector Location: Bi-pressure pump 6 - Door activator, rear Removing 40 Installing 40

Page 57Page 57-

7 - Hose connector Location: in connector between door and Bpillar. 8 - T-connectors Location: B-pillar sill panel covered by sill molding. 9 - Door activator, front Removing 38 Installing 38

Page 57Page 57-

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Central locking, repairing (Sedan)

Page 3 of 14 57-33

Central locking, repairing (Wagon) 1 - Fuel tank flap activator To remove, remove right rear compartment trim and loosen right front trim Page 7053 Removing and installing Page 5737 2 - Foam tube 3 - T-connector Location: Fuel tank flap activator. 4 - Rear lid activator To remove, first remove rear lid trim Page 70-59

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Central locking, repairing (Sedan)

Page 4 of 14 57-34

5 - Sleeve 6 - Door activator, rear Removing 40 Installing 40

Page 57Page 57-

7 - Hose connector Location: in connector between door and pillar. 8 - Front door activator Removing 38 Installing 38

Page 57Page 57-

9 - T-connectors Location: B-pillar sill panel covered by sill molding. 10 - Bi-pressure pump Location: Recess in right rear vehicle floor.

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Central locking, repairing (Sedan)

Page 5 of 14 57-35

11 - T-connector Location: behind wheel house, right. 12 - T-connector Location: Wheel housing / backrest, covered by rear compartment trim.

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Central locking, repairing (Sedan)

Page 6 of 14 57-36

Bi-pressure pump, installing (Sedan) - Install pressure line. - Connect multi-pin connector to bi-pressure pump. Check for proper seating. - When inserting bi-pressure pump, connector -1(4-pin) must engage in clips. - When instaling bi-pressure pump be sure that water drain hose -2- for power roof is not pinched and is not pulled from grommet. After completed installation check routing of hose once more.

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Central locking, repairing (Sedan)

Page 7 of 14 57-37

Fuel tank flap activator, removing and installing - Remove screws -2- , swing activator -3- upward out of bracket -1- . - Disconnect pressure line -6- from activator. - Pull activator with locking rod -4- from rod guide 5-. - Perform function check before reinstalling luggage compartment carpeting.

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Central locking, repairing (Sedan)

Page 8 of 14 57-38

Front door activator, removing and installing Removing Remove door trim, move moisture barrier out of way Page 70-15 . Remove door inner controls and pull rod 57-22 .

Page

- Disconnect pressure line -3- from hose clips (4x) and disconnect from activator. - Open hinge -1- of activator and press out connector rod -5-. - Remove screws and remove activator upward. - Disconnect multi-pin connector. Installing - Install pressure line and multi-pin connector, connector must click into position. - Install activator with pre-inserted screws and tighten. - Hook pressure line into clips.

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Central locking, repairing (Sedan)

Page 9 of 14 57-39

- Install inside door handle and pull rod. - Activator and door lock must be in locked position (down) to install connector rod. Note: For the driver's door, the door lock latch must be in the closed position (second or main lock position). - Lock washer -3- must be locked into position arrows-. - Press in connector rod -1- without tension and close hinge -2-. CAUTION! Do not pull connector rod downward when pressing in.

- When locking, hinge -2- must turn lock washer -1and disengage. - Perform function check. - Install trim panel.

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Central locking, repairing (Sedan)

Page 10 of 14 57-40

Rear door activator, removing and installing Removing Remove door trim, partially remove moisture barrier Page 70-26 . - Disconnect hoses from clips -5-. - Disconnect connector rod -6-. - Remove screws -3- and remove activator downward and out. - Disconnect pressure hose -4- and multi-pin connector -7-. Installing - Connect pressure hose and multi-pin connector. Connector must engage in clip. - Insert activator with pre-installed screws and tighten screws. Note: Activator and door lock must be in locked position to install connector rod.

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Central locking, repairing (Sedan)

Page 11 of 14 57-41

- Striker plate -1- must be engaged -arrows-. - Connect hoses into clips. - Press in connecting rod tension-free and close hinge -2-. CAUTION! Do not pull connecting rod down when pressing into position. - When closing, hinge -1- must turn striker plate -2and cause it to engage. - Perform function test. - Install trim panel.

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Central locking, repairing (Sedan)

Page 12 of 14 57-42

Central locking system, functional check Notes: If the system is working properly, all locks must be locked in about 2 seconds. If the bi-pressure pump runs longer than 5 seconds, the system is leaking. With the linkages are not correctly adjusted, the switch-off point is not reached in the activator and the bi-pressure pump "pulsates". After a maximum of 35 seconds the control module must switch off the bi-pressure pump. Test requirements Doors, rear lid and fuel tank flap are closed. Door windows completely open. Locking system, checking - Push down lock knob on driver's door. Locking knobs on all doors must go down; all doors, the rear lid and the fuel filler flap are locked. - Check locking on all doors, rear lid and fuel filler flap. Note: Central locking and unlocking must be possible only using the locking knob at the driver's door.

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Central locking, repairing (Sedan)

Page 13 of 14 57-43

Anti-theft function, checking Requirements: Doors, rear lid and fuel tank flap are closed. Door windows completely open. Anti-theft function, checking - Lock driver's door with key and within 12 seconds pull up all locking knobs. 12 seconds after unlocking, the central locking system pump and control module V69- must run and all doors must be locked again. - After another 15 seconds, pull up all door locking knobs one after the other (wait at least 24 seconds after locking with key) It must not be possible to pull the locking knobs into the unlocked position (up to 8 mm is OK). At the same time the pump must start up to pull the locking knobs back.

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Central locking, repairing (Sedan)

Page 14 of 14 57-44

At the time one of the locking knobs is pulled, an audible locking sound must be heard (safety solenoids are blocking the locking rods). The doors are locked and secure, the rear lid and the fuel filler flap are locked. - Repeat test starting with passenger's door.

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Rear door assembly

Page 1 of 24 58-1

Rear door assembly Door, repairing 1 - Door Removing and installing Page 58-5 Adjusting: at hinge within oversized holes. 2 - Inner window channel Pushed onto flange. 3 - Door window glass Removing and installing Page 58-7 Lift rail at window glass, dimension Page 58-11 4 - Outer window channel Buttoned into window frame. Cannot be removed without destroying it. Removing 9 Installing 10

Page 58Page 58-

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Rear door assembly

Page 2 of 24 58-2

5 - Cover 6 - Bolt 7 Nm (62 in. lb) 7 - Window channel Pull up and out of window slot. 8 - Window regulator Removing and installing Page 58-6 Installing glass to window regulator Page 58-8 9 - Catch pin 10 - Clip two-piece 11 - Seal Outer securing clip additionally bonded (front edge of door).

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Rear door assembly

Page 3 of 24 58-3

12 - Door lock strap boot 13 - Bolt 7 Nm (62 in. lb) 14 - Door check strap 15 - Nut 6.5 Nm (58 in. lb) 16 - Clip 17 - Multi-pin connector Separation point for all electrical and pneumatic connections. Remove coupling nut and pull off. 18 - Door check strap cover Self-adhesive, is stuck to B-pillar.

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Rear door assembly

Page 4 of 24 58-4

19 - Bolt 55 Nm (41 ft lb) 20 - Door hinge Bolted to door, inserted toward B-pillar and secured with grub screw. 21 - Inner window slot seal Pushed onto flange. 22 - Outer window slot seal Pushed onto flange.

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Rear door assembly

Page 5 of 24 58-5

Door, removing and installing With central locking and /or power windows. - Disconnect multi-pin connector -1- on B-pillar. - Remove nut -2- and remove pin. - Remove grub screw -arrow- from upper and lower hinge. - Lift door up and out of hinge brackets. Notes: Clean bolt thread with wire brush and nut thread with thread chaser. Coat bolt thread with locking fluid D 185 400 A 2. Tighten nut -2- with 6.5 Nm (58 in.lb).

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Rear door assembly

Page 6 of 24 58-6

Window regulator, removing and installing - Unbolt window glass from window regulator. - Push door window up and fasten in position with adhesive tape. - Remove bolts and remove window regulator. - For power windows, disconnect connector Note: Door glass to window regulator, installing 8.

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Rear door assembly

Page 7 of 24 58-7

Door window glass, removing and installing - Lower window. - Remove trim panels (triangular trim inside and outside). - Remove window channel -1- and take up and out of window slot. - Remove window glass from window regulator.

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Rear door assembly

Page 8 of 24 58-8

Door window glass, installing - Install glass hand-tight to window regulator. - Raise window fully and then lower again slightly. - Lift window at front slightly to avoid it running out of window channel. - Tighten bolts -arrows- through opening, 7 Nm (62 in. lb).

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Rear door assembly

Page 9 of 24 58-9

Outer window channel, removing - Remove triangular trim plates. - Pull off outer window slot seal from flange. - Pull off inner window slot seal from flange - Starting at rear top corner, pry off outer window channel from flange.

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Rear door assembly

Page 10 of 24 58-10

Outer window channel, installing - Install window channel into window slot in front and rear (arrow 1). - Press down on window channel and starting at top corner, press onto flange. - Retaining lip -arrow 2- must engage fully.

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Rear door assembly

Page 11 of 24 58-11

Lift channel, installing on window glass - Press lift channel onto glass: a

384 mm.

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Rear door assembly

Page 12 of 24 58-12

Rear window regulator, servicing - Rear window regulators, removing 6.

Page 58-

- Remove screws for gear cover -arrows-.

- Pull cable drum off gear housing in direction of arrow by rocking slightly in alternate direction.

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Rear door assembly

Page 13 of 24 58-13

- Pull off cover of new motor in direction of arrow. Note: Surfaces covered with grease must not be contaminated with dirt or dust. For additional grease use G 000 450 02.

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Rear door assembly

Page 14 of 24 58-14

- Pull drive gear off gear shaft in direction of arrow. Note spacer washer. CAUTION! The damping element -1- must fit exactly in the recesses of the cable drum.

- Install drive gear -2- in cable drum. Install spacer washer -3- onto drive gear.

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Rear door assembly

Page 15 of 24 58-15

- Install motor for window regulator together with cable drum in direction of arrow.

- If cable drum and gear housing are difficult to be joined to stop, turn drive gear by slightly pushing follower until drive gear engages.

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Rear door assembly

Page 16 of 24 58-16

- Check correct cable position on cable drum.

- Install screw and tighten in numbered sequence to 3 Nm (27 in. lb). Notes: Before installing window regulator, check proper functioning. Replacement of mechanical parts (linkages, cable) is done in the same way.

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Rear door assembly

Page 17 of 24 58-17

Side reinforcement, removing and installing Note: Remove door trim, moisture barrier and protective strip. 1 - Side reinforcement Removing: - Remove Torx bolts 3 -. - Slide side reinforcement forward (arrow -A-) and then guide it backward and up (arrow -B-). - First remove front of reinforcement bar from door (arrow -C). 2 - Catch pin 3 - Torx bolt

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Rear door assembly

Page 18 of 24 58-18

Door lock assembly 1 - Locking knob 2 - Inner release handle Removing 23

Page 58-

3 - Backing plate 4 - Door handle Removing and installing Page 5821 5 - Clip 6 - Backing plate 7 - Screw 7 Nm (62 in. lb) Right side: left-hand thread, flat black finish.

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Rear door assembly

Page 19 of 24 58-19

8 - Screw 20 Nm (15 ft lb) 9 - Dished spring washer Collar must face outward. 10 - Plastic washer 11 - Striker pin 50 Nm (37 ft lb) 12 - Door lock Removing and installing Page 5822 Free play adjustment Page 57-28 13 - Backing plate Only install with matching door lock.

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Rear door assembly

Page 20 of 24 58-20

14 - Locking lever 15 - Clip 16 - Pull rod Attach to door release mechanism from below. 17 - Locking rod 18 - Anti-theft protection 19 - Spreader rivet 20 - Relay lever

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Rear door assembly

Page 21 of 24 58-21

Door handle, removing and installing With central locking system: Remove rear trim, carefully remove moisture barrier at the rear and disconnect electrical connector. Note: Right screw has left-hand thread and flat black finish. - Remove screw -1- (7 Nm (62 in. lb). - Push door handle in direction of arrow and swivel out of door. Installation note: - Check backing plate -2- and clip -3- for damage.

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12/7/2004

Rear door assembly

Page 22 of 24 58-22

Door lock, removing and installing Note: The hole on the rear door lock is covered up by the lever for child safety lock - Unclip cover cap. - Remove screw. - To remove and install, lock operating lever -1- on side with screwdriver. - Press locking sleeve off door lock.

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12/7/2004

Rear door assembly

Page 23 of 24 58-23

Inner release handle, removing - Press out securing clip from hole in door panel. - Press out release handle in driving direction from securing holes.

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12/7/2004

Rear door assembly

Page 24 of 24 58-24

Door inner seal, removing - Remove door trim

Page 70-38 .

Door trim -1- covers door inner seal. - Joint -2- is under door sill plate. Dimension a 360 20 mm.

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12/7/2004

Sliding/tilting roof

Page 1 of 20 60-1

Sliding/tilting roof Special tools and equipment 3195 Installation lever

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12/7/2004

Sliding/tilting roof

Page 2 of 20 60-2

Sliding/tilting roof, component overview 1 - Panel for sliding/tilting roof Removing 6

Page 60-

Installing

Page 60-8

Adjusting 10

Page 60-

2 - Panel seal Seal joint is in the center of right side section. 3 - Flap for flap headliner 4 - Screws 5 - Headliner for flap (includes flap - 3 -) Removing 12

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Page 60-

12/7/2004

Sliding/tilting roof

Page 3 of 20 60-3

6 - Sliding/tilting roof assembly Removing 16

Page 60-

Assembly contains the following parts: - U-frame with guide channels. (If required, grease guide channels only with special grease G 000 450 02, otherwise function may be impaired. Never use multipurpose grease.) - Cable guides, rear with cables - Guides, front 7 - Spacer plate 8 - Cable drive (electrical) Cable drive, checking parking position Page 60-15

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12/7/2004

Sliding/tilting roof

Page 4 of 20 60-4

9 - Counter-sunk screws (coated) Before installing, clean threads with wire brush and coat with locking fluid D 185 400 A2. 3 Nm (27 in.lb) 10 - Wind deflector mounting screws 11 - Threaded plug Thread must point slanted to the rear. 12 - Wind deflector Move panel to the rear to remove wind deflector. 13 - Tilt lever spring 14 - Circlip 15 - Tilt lever Tilt lever must press on guide rail through spring pressure.

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12/7/2004

Sliding/tilting roof

Page 5 of 20 60-5

16 - Locking lever spring 17 - Locking lever 18 - Circlip 19 - Adjusting plate Part of sliding block. 20 - Torx screw (Torx key T 25) Note installation position Page 60-9 6 Nm (53 in. lb) 21 - Water drain hose Cleaning 19

Page 60-

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12/7/2004

Sliding/tilting roof

Page 6 of 20 60-6

Sliding/tilting roof panel, removing - Tilt sliding/tilting roof up. - Pull down panel -1- with special tool 3195 until the special tool -2- can be engaged into flap liner -3-.

- Pull off flap liner with special tool 3195 from guides (arrow). Pound with your fist on special tool until flap liner disengages. Push it back until special tool touches roof opening. - Disengage tool and push flap liner back fully.

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Sliding/tilting roof

Page 7 of 20 60-7

- Remove Torx screw -1- (Torx key T25). Note: Adjustment plates are part of the connecting piece guide. - Remove roof panel up and out.

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12/7/2004

Sliding/tilting roof

Page 8 of 20 60-8

Sliding/tilting roof panel, installing Move panel to "0 position" (parked position). 0-position Pins -3- must be within notches (arrow). Locking levers -4- must be engaged in the guide rails. If not, Parallel alignment, checking and adjusting, Page 60-10 .

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12/7/2004

Sliding/tilting roof

Page 9 of 20 60-9

- Position panel from above and install screws between sliding block and panel. - Slightly tighten screws (Torx key T25). Notes for installation: When inserting Torx screws -1- note correct position of adjustment plate -2-. Guide pins -3- are located in the elongated holes of the adjustment plate. Tighten screws after glass panel height adjustment (6 Nm). Glass panel height adjustment Page 60-14 .

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12/7/2004

Sliding/tilting roof

Page 10 of 20 60-10

Parallel alignment, checking and adjusting Checking and adjusting can be done with installed panel and pushed back panel liner. - Disconnect battery ground cable - Unclip interior light and remove cover for cable drive. - Remove cable drive (screws are coated). Before installing, clean threads with wire brush and coat with locking fluid D 185 400 A 2. - Tightening torque = 3 Nm (27 in. lb). Note: The drive gear must not be engaged with the cables.

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12/7/2004

Sliding/tilting roof

Page 11 of 20 60-11

- Slide rear guides from front to rear only to markings (notches) (arrows). - Pins -3- must be within markings (arrows). - Locking hooks -4- must be engaged in guide rails.

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12/7/2004

Sliding/tilting roof

Page 12 of 20 60-12

Flap headliner, removing - Tilt up sliding/tilting roof. - Pull down panel -1- with special tool 3195 until special tool -2- can be engaged into flap headliner -3-.

- Pull off liner with special tool 3195 from guides (arrow). Pound with your fist on special tool until liner disengages. Push it back until special tool touches roof opening. - Disengage tool and push liner back fully.

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12/7/2004

Sliding/tilting roof

Page 13 of 20 60-13

- Remove panel for sliding/tilting roof - Lift flap headliner -3- slightly and turn by 90 remove toward front from roof opening.

and

- Installation is in reverse order of removal.

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12/7/2004

Sliding/tilting roof

Page 14 of 20 60-14

Panel for sliding/tilting roof, adjusting height - Check parallel alignment at rear, if necessary adjust Page 60-10 . - To prevent wind noise, adjust height at front and rear according to illustration. - Check height adjustment at end of radii of roof opening toward vehicle center. Panel must not be higher at front or lower at rear than roof. Panel adjustment front: a = 1 mm lower than roof. Arrow

direction of travel

Panel adjustment rear: b = 1 mm higher than roof. Arrow

direction of travel

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12/7/2004

Sliding/tilting roof

Page 15 of 20 60-15

Cable drive, checking 0position If the cable is replaced, the cable drive must be installed in the "0-position" (panel for sliding/tilting roof closed). - Operate switch -1- and count revolutions of drive pinion -2-: "0-position" of cable drive is between end switch-off points -A- and -B-. End switch-off point is obtained by turning drive pinion clockwise. End switch-off point -B- is obtained by turning pinion counter-clockwise. -A- End switch-off point for tiltup function 2 turns to 0position. -B- End switch-off point for sliding function 9 turns to 0position.

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12/7/2004

Sliding/tilting roof

Page 16 of 20 60-16

Sliding/tilting roof assembly, removing - Disconnect battery ground cable. - Unclip interior light. - Remove screws -1- and -2- and disengage cover for cable drive in direction of arrow. Note: Screw -1- also secures bracket -3-. - Pull beading off molded headliner cut-out. To help in installation of replacement part, beading comes with a cord in clamping channel. Notes: When installing, a space remains in the area of the cable drive. a 180 mm. The space is marked by notches in the frame. - Remove trim on A-pillar, top of B-pillar, top of Cpillar and D-pillar. - Remove headliner.

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12/7/2004

Sliding/tilting roof

Page 17 of 20 60-17

- Remove water drain hoses from assembly. - Remove cable drive. - Remove glass panel for easier access Page 6025 . - Remove bolts and with help of second technician lift assembly out. Note: The assembly can also be removed as one unit.

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12/7/2004

Sliding/tilting roof

Page 18 of 20 60-18

Assembly, installing - Place roof assembly frame on rear mounting and move upward (three locating bolts must engage into mounting holes). - Fasten frame assembly 7.5 Nm (66 in. lb). Note: If you are checking the function without the headliner, install the beading first Page 60-16 .

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12/7/2004

Sliding/tilting roof

Page 19 of 20 60-19

Water drain hoses, cleaning Front drain hoses The front water drain hose -1is routed in the A-pillar and ends between the wheel housing and wheel liner. Cleaning is done from the opening in the sunroof. 1 - Front drain hose Only visible when wheel house liner is removed. 2 - Grommet for water drain hose

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12/7/2004

Sliding/tilting roof

Page 20 of 20 60-20

Rear drain hoses The rear water drain hoses -3are routed in the D-pillars and end on the sides of the bumper covers. Cleaning is done from the lower hose end. For this the bumper must be removed. 3 - Water drain hose 4 - Grommet for water drain hose 5 - Vent flap Note: For cleaning use a snake wire or old speedometer cable, about as long as the drain hoses. Remove the vent flaps first.

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12/7/2004

Sliding/tilting roof with glass panel

Page 1 of 15 60-21

Sliding/tilting roof with glass panel Assembly overview 1 - Glass panel for sliding/tilting roof (single pane safety glass) Glass panel for sliding/tilting roof, removing Page 6025 Glass panel for sliding/tilting roof, installing Page 6027 Glass panel for sliding/tilting roof, adjusting Page 6032 2 - Panel seal Adjusting 26

Page 60-

Seal joint is in center right area. Treat panel seal clamping channel with water as lubricant before installing.

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12/7/2004

Sliding/tilting roof with glass panel

Page 2 of 15 60-22

3 - Sliding headliner Removing and and installing Page 6028 4 - Trim frame Removing Glass panel, removing 5 - Sliding/tilting roof assembly frame Removing 16

Page 60-

Assembly consists of the following parts: - U-frame with guide channels. If necessary grease guide channels only with G 000 450 02 , otherwise function may be impaired. Do not use multipurpose grease. - Rear guides with cables - Front guides

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12/7/2004

Sliding/tilting roof with glass panel

Page 3 of 15 60-23

6 - Spacer plate 7 - Threaded piece for wind deflector mounting Thread must slant and point to rear. 8 - Wind deflector To remove, open panel to rear. 9 - Screws for wind deflector 10 - Countersunk screws (coated) Always use new screws. 3 Nm (27 in. lb) 11 - Cable drive 0-position, checking Page 60-34 12 - Locking lever

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12/7/2004

Sliding/tilting roof with glass panel

Page 4 of 15 60-24

13 - Locking lever spring 14 - Torx screw Torx key T25 6 Nm (26 in. lb) 15 - Adjusting plate Part of frame 16 - Water drain hoses Cleaning 19

Page 60-

17 - Spacer shims Attached to frame assembly.

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12/7/2004

Sliding/tilting roof with glass panel

Page 5 of 15 60-25

Sliding/tilting roof glass panel, removing - Slide headliner -1- to rear. - Slide trim frame -2- to the rear (clipped on in area of front guide -A- and guided at rear by guide -B-).

- Remove screws -1- (Torx key T25). - Remove panel up and out.

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12/7/2004

Sliding/tilting roof with glass panel

Page 6 of 15 60-26

Panel seal, adjusting - Using a 0,3 mm thick paper strip (business card), check that pre-tension between panel seal -1- and body -4- is uniform all-around. It must be possible for paper strip to be pulled through under tension. - If pre-tension is not enough, push panel seal apart using a wedge -3-. If pre-tension is too high, press it together. To adjust panel seal, glass panel -2must be removed.

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12/7/2004

Sliding/tilting roof with glass panel

Page 7 of 15 60-27

Glass panel for siding/tilting roof, installing Panel must be installed in 0-position (sunroof closed). 0-position: Pins -3- must line up with notches (arrow). Locating hooks -4- must be locked in guide rails. If not, adjust parallel alignment

Page 60-31

- Place sliding/tilting roof from above and install mounting screws for frame/panel. - Slightly tighten screws (Torx T 25). Notes: When tightening Torx screws -1- be sure that adjustment plate is properly located (adjustment plate is an integral part of guide channels) . Tighten screws after adjusting panel height to 6 Nm (53 in. lb).

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12/7/2004

Sliding/tilting roof with glass panel

Page 8 of 15 60-28

Sliding headliner, removing Glass panel and trim frame removed and sliding/tilting roof in "closed position". - Remove glider -1- from from sliding headliner (only one side) and pull out of frame assembly guide channels.

- Release spring -2- and pull sliding headliner toward front out of roof opening.(When pulling out , sliding headliner must be tilted). Spring -2- is not visible when installed.

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12/7/2004

Sliding/tilting roof with glass panel

Page 9 of 15 60-29

Sliding headliner, installing - Install springs -2- to sliding headliner. Always use new screws (screws are coated). - Insert sliding headliner into roof cutout. Fasten slide in guide channel (slide is screwed onto sliding headliner. Insert slider for other side and fasten to sliding headliner. - Move sliding headliner to rear until springs -2engage.

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12/7/2004

Sliding/tilting roof with glass panel

Page 10 of 15 60-30

Parallel alignment, checking Glass panel must be closed. - Push sliding headliner fully back. - Push trim frame to rear (clipped on in area of front guide and guided in rear by pins). Pins -3- must be positioned within notches (arrows). Hooks -4- must be engaged in guide rails. If pins -3are not positioned within notches, parallel alignment must be adjusted Page 60-31 .

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12/7/2004

Sliding/tilting roof with glass panel

Page 11 of 15 60-31

Parallel alignment, adjusting Glass panel must be closed. - Disconnect battery ground cable. - Fully push back sliding headliner and trim frame. - Remove cover for cable drive. - Remove cable drive assembly. Always use new screws (coated) when installing cable drive 3 Nm (27 in. lb). Note: The drive pinion must no longer be engaged in the drive cables. - Push rear guides only from the rear onto notches (arrows). Pins -3- must be positioned within notches (arrows). Hooks -4- must be engaged in guide rails.

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12/7/2004

Sliding/tilting roof with glass panel

Page 12 of 15 60-32

Glass panel for sliding/tilting roof, adjusting height Parallel alignment must be OK. - Tilt glass panel up. - Push sliding headliner fully back. - Release trim frame and push to rear. - Move glass panel to 0-position. - Loosen all four screws on glass panel (floating alignment in roof opening). - Adjust height from front to rear according to illustration to avoid wind noise. Glass panel adjustment, front: a

1 mm lower than roof

Arrow

driving direction

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12/7/2004

Sliding/tilting roof with glass panel

Page 13 of 15 60-33

Glass panel adjustment, rear: b

1 mm higher than roof

Arrow

driving direction

- Tighten screws for glass panel to 6 Nm (53 in. lb). - Push trim frame forward and clip in (clipped-in in front frame and guided in rear by pins).

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12/7/2004

Sliding/tilting roof with glass panel

Page 14 of 15 60-34

Cable drive, checking 0position If you replace the cable drive, it must be installed in the "0position" (glass panel closed). - Connect cable drive wiring harness connector to sliding/tilting roof harness connector. - Operate switch -1- and count revolutions of drive pinion -2-: "0-position" of cable drive is between end switch-off points -A- and -B-. - End switch-off point -B- is obtained by turning drive pinion clockwise and end switch-off point -A- by turning counter-clockwise. -A- End switch-off point for tilt function 2 revolutions to 0position. -B- End switch-off point for tilt function 8.25 revolutions to 0-position.

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12/7/2004

Sliding/tilting roof with glass panel

Page 15 of 15 60-35

Sliding/tilting roof assembly Removing

Page 60-16

Water drain hoses Cleaning

Page 60-16

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12/7/2004

Bumpers

Page 1 of 5 63-1

Bumpers Front bumper, removing and installing CAUTION! Do not drive vehicle without bumper or bumper brackets because subframe will no longer be properly secured. 1 - Trim cover 2 - Cover Removing bumper from long member Page 63-4 3 - Carrier 4 - Guide To remove or install bumper, pull out or push in bumper parallel to guides at left and right.

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12/7/2004

Bumpers

Page 2 of 5 63-2

5 - Bracket 6 - Bolts 82 Nm (60 ft lb) 7 - Spreader clip 8 - Bolt and washer assembly Connects cover to wheel housing liner. Qty. 4 each side. 9 - Bolts 23 Nm (17 ft lb) 10 - Air intake grille Removing 3

Page 63-

11 - Spoiler Clipped into cover.

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12/7/2004

Bumpers

Page 3 of 5 63-3

Air intake grille, removing - Remove screws -1- (qty. 2). - Press down detent lugs -2- with screwdriver. - Tilt air intake grille toward the front and out.

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12/7/2004

Bumpers

Page 4 of 5 63-4

Front bumper, removing from side member - Remove bolts on left and right. Vehicles with fog lights: - Disconnect electrical connector from back side of fog lights. Vehicles with headlight washer system: - Pull bumper slightly forward and disconnect hose from connector between bumper and cross panel.

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12/7/2004

Bumpers

Page 5 of 5 63-5

Continuation for all vehicles: - Remove bolts (arrows) 82 Nm (60 ft lb). - Pull out bumper toward front parallel from guides on sides.

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12/7/2004

Rear bumper, removing and installing

Page 1 of 2 63-6

Rear bumper, removing and installing Removing: - Remove bolts -2-, accessible from luggage compartment. - Remove bolts - 7 - (qty. 5), accessible from under vehicle. 1 - Bolt 23 Nm 17 ft lb) 2 - Bolts Accessible from luggage compartment 82 Nm (60 ft lb) Wrench size: 16 mm 3 - Bracket 4 - Carrier

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12/7/2004

Rear bumper, removing and installing

Page 2 of 2 63-7

5 - Guide To remove or install bumper, pull out or push in bumper parallel to guides at left and right. 6 - Cover 7 - Self-tapping screw 8 - Under-body cover Secured with selftapping screws - 7 -. 9 - Torx bolt T 20

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12/7/2004

Flush-bonded windows

Page 1 of 28 64-1

Flush-bonded windows Special tools VAG1474 A Cutting device for bonded windows VAG1344 Double suction cups VAG1351 Cutting tool VAG1755 Window removal set VAG1628 Hand gun VAG1939 Cartridge heater

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12/7/2004

Flush-bonded windows

Page 2 of 28 64-2

VAG1561 A Electric cutter VAG1561/2 Cutting knife VAG1561/3 Cutting knife VAG1561/8 Cutting knife VAG1561/10 Cutting knife VAS5237 Caulking gun

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12/7/2004

Flush-bonded windows

Page 3 of 28 64-3

Only pre-coated windows are supplied for repair work. Pre-coated windows: Pre-coating means that the PUR adhesive must be applied to window and window surround. Before applying 2K-adhesive, the pre-coating must be treated with activator D 181 801 A1. The pre-coated window does not need to be primed. CAUTION! Do not get activator on painted body parts otherwise the paint will be damaged.

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12/7/2004

Flush-bonded windows

Page 4 of 28 64-4

Materials 2K- window adhesive

DA 004 600 A2 2),

1K- window adhesive

DH 009 100 03 4),

Activator

D 181 801 A1 1)

Glass primer/paint primer

3)

5)

D 009 200 02 1)

Cleaning solution

D 009 401 04 1)

Primer applicator

D 009 500 25 1)

Adhesive remover

D 002 000 10 1) 357 853 999

Cutting cord

357 845 955

Cutting wire 1)

Materials come in box D 004 700

2)

Note curing time

3)

Use caulking gun VAS5237 to apply.

Page 64-26

4)

Heat according to maunufacturer's specifications using cartridge heater VAG1939. 5)

Small cartridge 110 ml for sealing or when 400 ml cartridge is not enough.

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12/7/2004

Flush-bonded windows

Page 5 of 28 64-5

Windshield, removing and installing 1 - Windshield Windshield, removing Page 64-7 Windshield, installing Page 64-9 2 - Seal Self-adhesive Bonding

Page 64-9

3 - PUR-adhesive sealant Cross section of bead: Width 7 mm; height 11 mm (including pre-coating and remaining material on window and window flange).

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Flush-bonded windows

Page 6 of 28 64-6

4 - Cutting thread Insert all around in surround. 5 - Tube section 6 - Surround (single piece) Replacing 11

Page 64-

7 - Thread end 200to 250 mm long

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Flush-bonded windows

Page 7 of 28 64-7

Windshield, removing - Remove trim panels on A-pillar

Page 70-34 .

- Turn interior rear view mirror with mirror base 15 20 away from installation position. - Remove sunvisor -2- .

For illuminated mirror also disconnect electrical connector in roof frame. - Remove mounting -1-, turn 90 frame.

and pull out of roof

If sliding/tilting roof is installed, also remove cover for cable drive. - Lower headliner at front.

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Flush-bonded windows

Page 8 of 28 64-8

- Remove sealing strips at bottom center of windshield. - Free thread ends. - Place winding device VAG1654 in position 1 , aim for an acute cutting angle. - Cut evenly until at level with winding device. Ensure sufficient clearance between cutting thread and instrument panel. - Move winding device according to individual positions. Notes: Ensure sufficient clearance for the cutting thread in the area of the roof/molded headliner. If the windshield cannot be removed from the opening (adhesive has spread to the outside beyond the thread channel) it is advisable to cut through the remaining bonding with a piece of cutting thread using two pull toggles in order to prevent damage to the paintwork. Always guide the cutting thread below the window surround. Cut off the tube section carefully from the window surround with a knife.

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Flush-bonded windows

Page 9 of 28 64-9

Windshield, installing The replacement windshield comes with the following: 1 - Windshield 2 - Ceramic coating 3 - PUR primer 4 - Cutting thread 5 - Surround

- Bond sealing section -1- to limit line - ceramic coating / screen print -2-. Spare ends must terminate at side before pre-coating.

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Flush-bonded windows

Page 10 of 28 64-10

Preparing old undamaged window for glazing Page 64-22 . Preparing new window for glazing 23 .

Page 64-

Preparing body flange for glazing 24 .

Page 64-

Curing time

Page 64-26 .

Installation note

Page 64-25 .

- Press in window until surround is flush with roof and A-pillars. - Secure with adhesive tape during curing.

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Flush-bonded windows

Page 11 of 28 64-11

Window surround, replacing When re-using an undamaged window, pull off the surround beginning in the sleeve area. Scrape off remaining material with a commercially available glass scraper down to a few tenths of a millimeter. Do not damage primer and ceramic layer when performing this step. - Replace window surround and install new cutting thread. Note: The remaining material acts as the adhesive base for the new adhesive sealant which has to be applied. CAUTION! Do not prime adhesive surfaces, do not activate and do not treat with cleaning solution. Keep adhesive surfaces clean from dirt and grease. Exception: If adhesion is not done immediately after cutting back, the residual adhesive must be activated with activator D 181 801 A1. - Apply adhesive all around to pre-coating and window surround. Width

6 - 7 mm

Height 11 - 13 mm (including pre-coating, remaining material on window and window flange).

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Flush-bonded windows

Page 12 of 28 64-12

Rear Window, removing and installing (Sedan) 1 - Rear window Rear window, removing Page 6415 Rear window, installing Page 64-16 2 - Frame (side and top) Replacing 11

Page 64-

Inserted cutting thread separates area of roof and D-pillars. Thread ends, colored black. Thread ends are positioned parallel to adhesive bead of Dpillars or behind parcel shelf. 3 - Tube section (side and top only) After curing, peel off protective paper and press down.

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Flush-bonded windows

Page 13 of 28 64-13

4 - Cutting thread 5 - PUR-adhesive sealant Cross section of bead: Width

7 mm

Height 12 mm (including pre-coating, residual material on window and window flange). 6 - Lower surround Inserted cutting thread separates lower area. Ends of threads are colored yellow. Ends of thread are positioned parallel to adhesive bead at Dpillar or behind parcel shelf. Replacing 11

Page 64-

7 - Trim strip Replace after removing. Install trim plate only after a newly installed window has cured.

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Flush-bonded windows

Page 14 of 28 64-14

Broken rear window, removing - Remove trim from D-pillars, parcel shelf and finishing strip (headliner/rear window) beginning at Page 70-46 . Note: Removing the parcel shelf is only necessary to clean-up broken glass. - Protect body and interior from glass splinters. - Remove glass pieces down to adhesive sealant material. - Remove connectors for heated rear window and antenna. - Cut out remaining glass with cutting tool VAG1351 or electric cutter VAG1561 with blade VAG1561/1. CAUTION! Mask off the rear window opening when working with a cutting tool or electric cutter. Wear protective goggles and leather gloves.

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Flush-bonded windows

Page 15 of 28 64-15

Undamaged window, removing - Place winding device VAG1654 in position 1. - Attach ends of thread (yellow) to winding device. - Move winding device to various positions and cut out window up to position 3. - Cut position 4 with other thread end.

- Cut through remaining adhesive, positions 1 - 3. - Cut away positions 4 and 5 with other free end of thread. Note: If you cannot remove the rear window from the opening (adhesive has spread to the outside beyond the thread channel) it is best to cut through the remaining adhesive with a piece of cutting thread using two toggles to prevent damage to the paint. Always guide cutting thread below the window surround.

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Flush-bonded windows

Page 16 of 28 64-16

Rear window, installing Preparing undamaged window for glazing Page 64-22 Preparing new window for glazing

Page 64-23

Preparing body flange for glazing

Page 64-24

Curing time

Page 64-26

- Press in window until window surround is flush with roof on top. - During curing time, protect window with adhesive tape. - At bottom, window must be at a body sheet metal.

1-2 mm over

1 - Surround for cover strip 2 - Body panel

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Flush-bonded windows

Page 17 of 28 64-17

Undamaged rear window, removing (Wagon) - Remove rear wiper arm. nut M8 lb)

15 Nm (11 ft

- Loosen sealing lip from window flange all around using plastic wedge. Spray with cleaning solution D 009 401 04 for lubrication. - With handle -1- , guide trimming needle -2- under sealing lip on side of window and puncture through adhesive bead. Do not get too close to the window, otherwise you may damage the heating element. - Remove handle and pass cutting thread through eye of needle. - Pull cutting thread through toward inside (use pliers and gloves). - Guide cutting thread between sealing lip and window flange using tube -3- (if thread breaks, use cutting wire).

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Flush-bonded windows

Page 18 of 28 64-18

- If gap is too small, guide cutting thread from outside and push under lip with a plastic wedge. - Place cutting thread around window as shown. Note: Press in cutting thread deep enough to avoid damaging sealing lip or spacer lip. - Secure outer end of thread on window wiper shaft or pull thread through toward inside and counterhold with handle VAG1351/1. - Disconnect heated rear window and press connecting tabs onto window. GL and GT only - Unclip trim panels on left and right parallel to rear window.

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Flush-bonded windows

Page 19 of 28 64-19

- Cover inside window flange -3- with textile reinforced tape when you use cutting wire. - Secure inner end of thread on winding device. - Place winding device VAG1654 in position 1. - Move winding device according to position required and cut out window glass. - Press cutting thread against window glass with plastic wedge during cutting to provide clearance at window flange.

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Flush-bonded windows

Page 20 of 28 64-20

Broken rear window, removing - Protect body and vehicle interior against glass splinters. - Remove glass fragments down to adhesive sealant. - Disconnect window heater and antenna. - Cover flange -2- all around with textile reinforced adhesive tape. - Cut through adhesive with glass remnants using electric cutter with blade VAG1561/10 with stop roller. CAUTION! Always wear protective goggles and leather gloves.

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Flush-bonded windows

Page 21 of 28 64-21

Rear window, installing Preparing old undamaged window for glazing Page 64-22 Preparing new window for glazing

Page 64-23

Preparing body flange for glazing

Page 64-24

Curing time

Page 64-26

Installation notes

Page 64-25

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Flush-bonded windows

Page 22 of 28 64-22

Undamaged rear window, preparing for installation Note: When re-using an undamaged window, cut back remaining adhesive sealer -1- shortly before re-use to 1 - 2 mm using electric cutter with blade VAG1561/10 and stop roller. Be careful not to damage pre-coating and lip with spacer rib -2-.

Do not damage spacer rib -1- and ceramic coating -2. CAUTION! Do not prime adhesive surfaces, do not activate and do not treat with cleaning solution. Keep adhesive surfaces clean from dirt and grease. Exception: If adhesion is not done immediately after cutting back, the residual adhesive must be activated with activator AMV 181 800 02.

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Flush-bonded windows

Page 23 of 28 64-23

New rear window, preparing for installation New windows are supplied already pre-coated with PUR. The pre-coating consists of items 1, 2 and 3. 1 - Sealing lip 2 - Spacer lip 3 - Area for applying adhesive bead 4 - Rear window - Rub off pre-coating with lint-free rag. CAUTION! Do not use primer on pre-coating and no cleaning solution. - Apply thin coat of activator AMV 181 800 02 with applicator -1- D 009 500 25 (felt ball with wire) only on pre-coating -2- of glass. - Allow applicator to flash off for at least 10 minutes. CAUTION! Do not let activator get onto paint or it will be damaged.

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Flush-bonded windows

Page 24 of 28 64-24

Body flange, preparing for window installation - Cut back remaining material on body flange with scraper blade VAG1561/8 but do not remove completely. Note: The remaining material acts as the adhesive base for the new adhesive sealant which has to be applied. Keep sealant free of dirt and grease. CAUTION! Do not prime adhesive surface, do not activate and do not apply cleaning solution. Always keep adhesive surfaces clean from dirt and grease. Exception: If adhesion is not done immediately after cutting back, the residual adhesive must be activated with activator D 181 801 A1. CAUTION! Do not get activator on painted body parts otherwise the paint will be damaged. If the body flange was repaired or partially replaced, clean the flange after painting and priming.

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Flush-bonded windows

Page 25 of 28 64-25

Rear window, installing Note: 1K window adhesive sealant DH 009 100 03 must be heated for 20 minutes in cartridge heater VAG1939. Installation hint: - Apply adhesive material all around to the precoating -1- at right angle to the rear window. CAUTION! Window must be inserted within 10 minutes, otherwise adhesion will be impaired. - Insert window using two double suction cups (VAG1344) in window opening and align.

- Press window in as far as spacer lip -2-. - Secure window with tape during curing. Existing labels (e.g. for airbag) can be attached.

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Flush-bonded windows

Page 26 of 28 64-26

Curing time CAUTION! Special requirements must be adhered to when replacing bonded windows. For example, after curing time, the integrity of newly bonded windows should comply with operation safety guidelines in case of an accident. The new 2K adhesive DA 004 600 A2 allows for a shortened curing time. Window type

Vehicle

Adhesivesealant

Windshield

with or without Airbag

DA 004 600 3 hours A2

Rear window

Curing time

DA 004 600 3 hours A2

Curing time: From bonding the window until driving the car. During the time of curing, the car must be stationary at room temperature (>15 C) and standing on level ground. CAUTION! The vehicle is safe to drive only after the curing time.

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Flush-bonded windows

Page 27 of 28 64-27

Paint repair The paint structure must be restored and, if necessary, corrosion protection must be applied. For paint damage in non-visible areas the following method is suitable: - Apply two coats (wet in wet) with glass/paint primer D 009 200 02 - flash-off time about 10 minutes.

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Flush-bonded windows

Page 28 of 28 64-28

Excess adhesive sealing material, cleaning Use adhesive remover D 002 000 10. Be sure to heed all cautions and warnings when using this material. CAUTION! When cleaning the inside of a freshly inserted window, be careful not to push the window outward. First, roughly clean painted surfaces with a dry rag. Clean remainder of paint surface with adhesive cleaner D 002 000 10. Cleaning plastic trim: Allow adhesive/sealer to harden (about 1 hour) and then peel off.

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Bolted windows

Page 1 of 2 64-29

Bolted windows Side window, removing and installing (Sedan) 1 - Side window To remove, first remove upper trim for B-pillar, upper trim for C-pillar, trim for Dpillar and cover for safety belt beginning on Page 70-38 . Insert side window first with pins into centering holes. 2 - Centering holes 3 - Nut 2.5 Nm (22 in. lb) Torque must be accurate. 4 - Threaded studs

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Bolted windows

Page 2 of 2 64-30

Side window, removing and installing (Wagon) 1 - Side window To remove, first remove upper trim for B-pillar, upper trim for C-pillar, trim for Dpillar, rear trim for luggage compartment and cover for safety belt beginning on Page 70-38 . Insert side window first with pins into centering holes. 2 - Centering holes 3 - Nuts 2.5 Nm The three nuts in area of D-pillar are mounted in the pillar. 4 - Threaded studs Note: Note the additional mounting point in the lower corner (arrow).

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Roof moldings

Page 1 of 6 66-1

Roof moldings Sedan 1 - Roof molding Removing - starting at windshield, pry off with soft plastic wedge Page 66-5 . Do not bend roof molding. Installing - replace clips, position roof molding on roof frame at windshield end (see sectional view) and drive in clips with palm of hand. 2 - Clip (7x) Replace - use only once. Removing 6

Page 66-

3 - T-stud 4 - Roof frame flange 5 - Surround with tube section (windshield) 6 - Roof frame

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Roof moldings

Page 2 of 6 66-2

Roof frame (Wagon) 1 - Roof molding without railing Removing - Starting at windshield pry off with soft wedge and pull forward out of end cap Page 66-5 . Do not bend roof molding. Installing - Always replace clips, position roof molding to roof frame/windshield (see sectional view) and drive into clips with palm of hand. Press on end caps firmly.

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Roof moldings

Page 3 of 6 66-3

2 - Roof molding with roof railing Removing: - Remove bolts and take off roof railing. - Unclip roof molding and pull toward front out of end cap Page 66-6 . Installing - Replace clips, position roof molding to roof frame/windshield and drive into clips with palm of hand. 3 - Clip (qty. 8) Replace - only use once. Removing 6

Page 66-

4 - End cap For new roof molding first clean adhesion surface on roof with cleaning solution D 009 401 04. Peel off protective paper and press on end cap firmly. When reinstalling and if remaining adhesive is not sufficient, use double-sided adhesive tape D 004 400, do not remove old foam adhesive tape.

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Roof moldings

Page 4 of 6 66-4

5 - Protective paper Remove after installation. 6 - Foam adhesive tape 7 - Installation position Gap without roof railing 4 2.5 mm. Gap with roof railing 5 2.5 mm. 8 - T-stud 9 - Roof frame flange 10 - Surround with tube section 11 - Roof frame 12 - Socket head bolt 9 Nm (7 ft lb)

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Roof moldings

Page 5 of 6 66-5

Roof molding, removing (without roof railing) - Pry off roof molding with soft plastic wedge.

Roof molding, removing (with roof railing) - Unclip roof molding by hand.

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Roof moldings

Page 6 of 6 66-6

Clip, replacing - Spread clip apart with screwdriver and remove clip.

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Roof railing, removing and installing

Page 1 of 2 66-7

Roof railing, removing and installing Note: The roof railing can be retrofitted. New moldings are required for this purpose. 1 - Roof railing Removing: - Remove socket head bolts and remove roof railing toward front. - Remove roof railing complete with mounting studs. Headliner removing Page 70-67 . - Remove nuts -6and remove roof railing upward. 2 - Socket head bolt 9 Nm (7 ft lb)

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Roof railing, removing and installing

Page 2 of 2 66-8

3 - Stud For removing or installing, first remove headliner. 4 - Teflon film 5 - Seal 6 - Nut 20 Nm (15 ft lb) For removing or installing, first remove headliner. 7 - Roof molding Removing and installing Page 66-5 8 - Not applicable 9 - Front mounting point for roof railing

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Radiator grille, removing and installing

Page 1 of 1 66-9

Radiator grille, removing and installing 1 - Radiator grille Material: ASA Removing: Release upper and lower locking lugs with screwdriver, pull grille off lock carrier. Installing: Align radiator grille with center locating point arrow- and clip in. 2 - Trim To remove, pry out trim frame. 3 - Guide 4 - Bolt/washer assembly 5 - Trim frame Painted in body color.

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Wheel housing liner

Page 1 of 1 66-10

Wheel housing liner - Remove radiator grille and trim Page 66-9 . - Remove bolts -1- (bolts connect wheel housing liner and front bumper cover). - Remove wheel house liner from wheel well. - Remove air conditioner reservoir (on left vehicle side if equipped with A/C).

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Exterior mirror

Page 1 of 3 66-11

Exterior mirror Special tools 80-200 Pry bar

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Exterior mirror

Page 2 of 3 66-12

Exterior mirror, assembly overview Note: To remove exterior mirror, first remove door trim panel. 1 - Mirror housing 2 - Screw 2 Nm (18 in. lb) 3 - Cover 4 - Adjustment mechanism (manual) 5 - Screw 6 - Boot

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Exterior mirror

Page 3 of 3 66-13

7 - Operating knob 8 - Mirror glass Clipped in (manual and electric). Removing - First press off mirror glass at bottom, then on top (special tool pry bar 80-200). Protect mirror against damage. Installing - Insert mirror with guide studs onto mountings and press on. Apply pressure only on center of mirror and be sure to wear protective gloves.

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Protective moldings

Page 1 of 1 66-14

Protective moldings 1 - Molding, front Clipped on 2 x Material: PP/EPDM 2 - Front door molding Clipped on 6 x Material: PP/EPDM 3 - Rear door molding Clipped on 5 x Material: PP/EPDM 4 - Rear molding Clipped on 2 x Material: PP/EPDM 5 - Clip for sleeve If sleeve is damaged, replace sleeve and clip. Insert clip with sleeve into molding.

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Inside mirror

Page 1 of 3 68-1

Inside mirror Inside mirror, removing and installing Removing - Twist inside mirror with base 15 installed position (arrow).

- 20

from

Installing - Position inside mirror with base 15 - 20 against installation position and turn until stop spring engages.

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Inside mirror

Page 2 of 3 68-2

Inside mirror, repairing using glass/metal adhesive Materials Glass-metal adhesive kit D 000 703 A1 Required tools 1 - Glass scraper (commercially available) 2 - Blade (commercially available) - Twist inside mirror 15 - 20 from installed position (arrow) and remove from base. - Clean PUR adhesive from mirror base using wire brush. - Remove spacer protrusion with emery paper (360/400 grain) placed on flat surface. - Keep ground-off surface free of dirt and grease. - Remove PUR adhesive material and primer from windshield down to ceramic coating using glass scraper. - Clean adhesive surface with adhesive remover D 002 000 10 or cleaning fluid D 009 401 04.

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Inside mirror

Page 3 of 3 68-3

CAUTION! Do not damage ceramic coating. Scratches will always be visible. - From the outside, mark position of mirror base on windshield. 1 - Notch must point up. 2 - Position mirror base in center of ceramic area 14 mm. - Cut nylon mesh fabric exactly according to size of mirror base. Note: Wear rubber gloves. - Apply adhesive evenly on mirror base. - Apply nylon mesh fabric on mirror base. - Apply additional adhesive on nylon mesh fabric by dabbing with tube. Press to the windshield.30 seconds from applying nylon mesh fabric on the adhesive. - Press mirror base firmly onto windshield for 15 seconds (do not use force). - Remove excess adhesive with rag. Note: The inside mirror can be installed after 15 minutes.

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Luggage compartment cover, removing and installing

Page 1 of 3 68-4

Luggage compartment cover, removing and installing 1 - Cover Cover can be secured to backrest felt covering with Velcro strip. 2 - Guide rail 3 - Self-tapping screw 4 - Countersunk screw 5 - Cover cap 6 - Spring nut 7 - Retaining bracket To remove and install, remove inertia reel cover and front luggage compartment trim Page 70-51 .

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12/7/2004

Luggage compartment cover, removing and installing

Page 2 of 3 68-5

8 - Securing bracket To remove and install remove rear luggage compartment trim panel Page 70-53 . 9 - Inertia reel cover Removing 50

Page 70-

10 - Rear luggage compartment trim panel Removing 53

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Page 70-

12/7/2004

Luggage compartment cover, removing and installing

Page 3 of 3 68-6

Luggage compartment cover, retrofitting - Remove front and rear luggage compartment trim from Page 70-51 . - Cut out marked openings in inertial reel cover and rear trim (holes for spring nut 9 mm wide, 13 mm high, center hole 16 mm diameter). Holes are marked on inside for PR No. 3U2. On vehicles without marking use guide rail as template. - Insert retaining bracket into inertia reel and fasten with screws. - Install securing bracket to side trim. - Reinstall trim. - Loosely install guide rails and align toward rear according to outside shape of trim. - Tighten all screws. - Install luggage cover.

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Screen separator wall, retrofitting

Page 1 of 8 68-7

Screen separator wall, retrofitting 1 - Reinforcement plate, upper front, Installing

Page 68-8

2 - Screen separator wall Installing 13

Page 68-

3 - Reinforcement plate, upper rear Installing

Page 68-9

4 - Securing eyes, lower rear Securing eyes are also existing eyes for child safety belt system. 5 - Securing eye, lower front Installing 10

Page 68-

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Screen separator wall, retrofitting

Page 2 of 8 68-8

Reinforcement plates and securing eyes, installing Note: Procedures are described for the right side, the left side is the same (mirror image). - Remove headliner

Page 70-62 .

Reinforcement plate, upper front, installing - Expose existing mounting points for reinforcement plate at roof header by removing tape -1-.

- Secure reinforcement plate -1- with rivets -2-. - Glue-in felt strip -3- as illustrated.

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Screen separator wall, retrofitting

Page 3 of 8 68-9

Reinforcement plate, upper rear, installing - Expose existing mounting points for reinforcement plate at roof header by removing tape -1-.

- Secure reinforcement plate -3- with rivets -1-. - Glue in felt strip -2- as illustrated.

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Screen separator wall, retrofitting

Page 4 of 8 68-10

Securing eye, lower front, installing - Remove rear seat bench

Page 72-32 .

- Cut out carpet at indentation -1- at seat crossmember on both right and left sides.

- Hold reinforcement plate -5- from rear against seat crossmember -4- and attach with rivets -3-. - Reinstall carpet. - Fasten securing eye -6- with bolts -1- and washers -2-.

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12/7/2004

Screen separator wall, retrofitting

Page 5 of 8 68-11

Openings for cover caps, cutting out Opening for cover caps in liner for C-pillar, cutting out - Cut out already marked opening on back side of trim -1-. For trim that does not have marked opening, cut trim using the following dimensions: a = 3 mm b = 20 mm c = 35 mm

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12/7/2004

Screen separator wall, retrofitting

Page 6 of 8 68-12

Opening for cover caps in liner for upper Dpillar, cutting out - Cut out already marked opening on back side of trim -1-.

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12/7/2004

Screen separator wall, retrofitting

Page 7 of 8 68-13

Screen separator wall, installing Top part of screen, installing - Insert upper bar at one side into holder in roof header and slightly push forward. - Insert other side of bar against spring tension into holder of roof header and also push slightly to front.

Lower part of screen, attaching to loading deck - Insert both strap hooks of lower bar into existing eyes (eyes for child safety belt system) on loading platform and tension by pulling on either strap end.

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12/7/2004

Screen separator wall, retrofitting

Page 8 of 8 68-14

Lower part of screen, attaching to foot well - Raise rear seat bench. - Attach tensioning straps to eyes on seat traverse bar and tension straps by pulling on applicable end. Screen separator wall, removing - To remove, first disengage tensioning straps. Push button marked "press" and pull strap through until hook can be disengaged. At top bar on one side pull slightly toward rear, repeat for other side and pull bar out of each bracket.

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12/7/2004

Safety restraint system

Page 1 of 1 69-1

Safety restraint system Vehicles with emergency tensioning seat belt retractors CAUTION! Testing, removing, installing and repairs must only be performed by qualified personnel. The pyrotechnic propellant has no expiration date. It has unlimited maintenance-free life. Belt tensioner components may not be opened or repaired. Always use new parts. Belt tensioner units that are mechanically damaged (dents or cracks) must be replaced. The belt tensioner unit should be installed immediately after removing it from its packaging. If work is interrupted, return belt tensioner to its package until work can continue. DO NOT leave a tensioner unit unattended if it has been removed from the package. The belt tensioner unit must not come in contact with grease, cleaning solutions or similar substances. Belt tensioner units must not be exposed to temperatures above above 100 C (212 F).

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12/7/2004

Seatbelts

Page 1 of 13 69-2

Seatbelts Front seat belts with emergency tensioning seat belt retractors, removing and installing CAUTION! Before starting any body disassembly, straightening or any other body repair or cutting work, remove the belt tensioning units. CAUTION! After an accident in which one or more belt tensioners were activated, both seat belts must be replaced (belts will no longer retract). 1 - Belt height adjustment fitting Removing 7

Page 69-

2 - Belt relay

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12/7/2004

Seatbelts

Page 2 of 13 69-3

3 - Cap Snapped on 4 - Belt guide Fastened with two screws. Tightening torque: 1.5 Nm (13 in.lb) 5 - Belt retractor To remove, remove upper and lower Bpillar trim and sill panel trim. Locking tabs determine position of belt tensioning unit. Bolt tightening torque: 40 Nm (30 ft lb) 6 - Front anchor Removing 8

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Page 69-

12/7/2004

Seatbelts

Page 3 of 13 69-4

7 - Tensioning unit Integral part of seat belt. Loosening locking nut - 9 - makes tensioner inactive, tightening nut reactivates tensioner. 8 - Bracket 9 - Locking nut Integral part of tensioning unit. 10 - Front belt buckle Removing 9

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Page 69-

12/7/2004

Seatbelts

Page 4 of 13 69-5

Belt retractor with tensioning unit, removing and installing CAUTION! Always follow prescribed work sequence for removing and installing belt retractor. 1 - Belt retractor 2 - Lock nut 23 Nm (17 ft lb) 3 - Tensioning unit 4 - Retainer 5 - Bolt 40 Nm (30 ft lb) 6 - Retaining slots Determine mounting position of belt retractors.

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12/7/2004

Seatbelts

Page 5 of 13 69-6

Removing - Remove sill plate. - Loosen lock nut - 2 - which will release tensioning unit 3 - and deactivate it. - Remove front trim 69-9 .

Page

- Remove cap from belt relay and remove relay. - Remove upper and lower trim from B-pillar. - Remove belt guide. - Remove belt retractor - 1 -. - Pull out tensioning unit - 3 from retainer - 4 -. CAUTION! Installation is done in the reverse of removal. Always follow the prescribed work sequence.

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12/7/2004

Seatbelts

Page 6 of 13 69-7

Seat belt height adjuster, removing and installing 1 - Cover Unclip 2 - Bolt 40 Nm (30 ft lb) 3 - Operating button Pull off 4 - socket-head bolt 23 Nm (17 ft lb) 5 - Belt height adjuster Removing: First remove trim for Bpillar.

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12/7/2004

Seatbelts

Page 7 of 13 69-8

Front belt anchor, removing 1 - Cap 2 - Bolt 40 Nm (30 ft lb) 3 - Spacer sleeve With belt anchor installed, left-hand belt as seen from above is turned 180 to the right. The right-hand belt as seen from above is turned 180 to the left.

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12/7/2004

Seatbelts

Page 8 of 13 69-9

Front belt latch, removing 1 - Bolt 60 Nm (44 ft lb) 2 - Slightly press off reinforcement plate and pull out belt latch -3-. 4 - Sliding plate 5 - Bolt 20 Nm (15 ft lb) Note: On seats with height adjustment, rivets are installed instead of bolts -5- .

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12/7/2004

Seatbelts

Page 9 of 13 69-10

Rear belt retractor, removing and installing 1 - Mounting bracket 2 - Nut 23 Nm (17 ft lb) 3 - Bolt 23 Nm (17 ft lb) Mounting bolt for shock absorber. 4 - Bolt 40 Nm (30 ft lb)

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12/7/2004

Seatbelts

Page 10 of 13 69-11

5 - Belt retractor Removing (sedan): Remove belt guide and belt cover Page 70-48 , remove bolt from luggage compartment. Removing (wagon): Remove belt guide, belt cover, rear luggage area trim and pull off from wheel well Page 70-51 . Installing: Locate belt retractor with pin in mounting bracket.

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12/7/2004

Seatbelts

Page 11 of 13 69-12

LATCH System "Lower Anchors and Tethers for CHildren", installing and retrofitting (Sedan) The LATCH system for "Lower Anchors and Tethers for CHildren" consists of the combination of rear upper tethers and rear lower anchors used to secure a child restraint. Rear top tether Installing: - Open rear lid - Locate pre-drilled hole in rear filler panel sheet metal. - Punch locating hole in rear filler trim panel from below. - Enlarge locating hole to 20 mm (25/32 in.) dia. - Install anchor components - Tighten nut to 23 Nm (17 ft lb) Rear lower anchor Note: This vehicle is not equipped with rear lower anchors.

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12/7/2004

Seatbelts

Page 12 of 13 69-13

LATCH System "Lower Anchors and Tethers for CHildren", installing and retrofitting (Wagon) The LATCH system for "Lower Anchors and Tethers for CHildren" consists of the combination of rear upper tethers and rear lower anchors used to secure a child restraint. Rear top tether There are 3 fastening eyes located at points -A- in the luggage compartment floor. The eyes are accessible through small flaps in the floor covering. Rear lower anchor Note: This vehicle is not equipped with rear lower anchors.

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12/7/2004

Seatbelts

Page 13 of 13 69-14

Front belt tensioning unit, deploying (disposal) WARNING! It is dangerous to scrap an unignited gas generator. The belt tensioner unit gas generator must be made unusable before scrapping. This is important because the gas generator is a pyrotechnic device that can cause injury if activated improperly (for instance when using a cutting torch). - Remove seat belt with belt tensioning unit Page 69-5 Use J-44210 Deployment Fixture and refer to the Airbag & Pyrotechnic Deployment Device Instruction Booklet for proper deployment procedure.

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12/7/2004

Seat belts, inspecting

Page 1 of 7 69-15

Seat belts, inspecting CAUTION! After every accident, the seatbelt system must be inspected thoroughly. If you find any damage according to the following check points, the customer must be informed about the need to have the affected belt(s) replaced. Check points: Check webbing of belt Check inertial reel (locking effect) Visually check belt lock Check belt lock function Check belt guides and lock tongue Check securing parts and anchorage points. Check lap belt automatic retractor. Note: If the customer refuses to have damaged seat belt system parts replaced, make appropriate notes on the customer's invoice.

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12/7/2004

Seat belts, inspecting

Page 2 of 7 69-16

Belt webbing, checking - Pull belt completely out of inertia reel or belt adjustment tongue. - Check belt for dirt, if necessary wash with mild soap solution also owner's manual. If either of the following damages (1 and 2) are found on an accident vehicle, replace belt complete with belt lock. If damages as shown under points 1, 2, or 3 are found on a vehicle not involved in an accident, it is sufficient to just replace the affected belt. 1 - Belt webbing cut, torn or chafed.

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12/7/2004

Seat belts, inspecting

Page 3 of 7 69-17

2 - Webbing loops on belt edge torn.

3 - Burn marks from cigarettes or similar.

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12/7/2004

Seat belts, inspecting

Page 4 of 7 69-18

Inertia reel locking effect, checking The inertia reel has two locking functions: The first locking function is applied when the belt is jerked out of reel (belt extraction acceleration). Checking - Pull belt out of inertia reel with firm jerk. If there is no locking effect, replace seat belt complete with belt latch. If there are difficulties with pulling out belt or reeling it in, check first whether the position of the inertia reel was changed. The second locking function is applied by changes in the vehicle movement (vehicledependent locking function). Checking - Fasten seat belt. CAUTION! Perform road test only on traffic-free road to be sure not to endanger other motorists or pedestrians. - Accelerate vehicle to 20 km/h (12 mph) and then step hard on foot brake. If the belt is not locked when braking, replace seat belt complete with belt latch.

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12/7/2004

Seat belts, inspecting

Page 5 of 7 69-19

Belt latch, visually checking - Check belt latch for cracks or other damage. If damaged, replace complete safety belt with belt latch. Belt latch, functionally checking Latch mechanism, checking: - Push locking tongue into belt latch until it engages with a click. Pull firmly on belt to be sure that locking mechanism is properly engaged. If belt tongue fails even once when checking 5 times, replace complete safety belt and latch.

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12/7/2004

Seat belts, inspecting

Page 6 of 7 69-20

Release mechanism, checking: - Release seat belt by pressing button on belt latch with finger pressure. When belt is slack, locking tongue must spring out of latch on its own. Perform test at least 5 times. If belt tongue fails even once to spring out of latch, replace complete seat belt with latch. CAUTION! Never use lubricants to eliminate noise or stiffness at belt latch buttons. Belt guides and locking tongues, checking Plastic covered guides show fine scoring after an accident when belt was worn. Wear caused by frequent belt use are smooth wear signs without scoring. - Inspect for deformation, breakage or cracks in plastic. If you find scoring or other damage, replace complete seat belt and latch.

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12/7/2004

Seat belts, inspecting

Page 7 of 7 69-21

Securing parts and anchorage points, checking Latch bracket deformed (stretched). Height adjustment does not work. Anchorage points (seat, pillar, vehicle floor) distorted or thread damage. If on any of these parts are damaged, replace safety belt complete with latch. Replace anchorage points. Note: Only replace damaged parts if damage was caused by wear and not by an accident.

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12/7/2004

Airbag

Page 1 of 15 69-22

Airbag Airbag system, components 1 - Airbag unit, driver's side Removing and installing Page 6926 2 - Data Link Connector (DLC) 3 - Airbag Malfunction Indicator Lamp (MIL) K754 - Airbag unit, passenger's side Removing and installing Page 6931 5 - Airbag Control Module -J234- mounted on tunnel Removing and installing Page 6935 6 - Central Ground point (behind instrument panel)

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12/7/2004

Airbag

Page 2 of 15 69-23

Safety precautions when working on the airbag system WARNING! Testing, removing, installing and repair work must only be performed by qualified, trained Service department personnel. Never use test lamp, voltmeter or ohmmeter for testing. Always disconnect the battery Ground (GND) strap before working on the airbag system. No waiting time is ncessary after disconnecting the battery. When connecting the airbag system to battery positive voltage (B+), there must be no person inside the vehicle. A technician must be electrostatically discharged before picking up (touching) an airbag unit . This is accomplished by touching a suitable metal part, for example, a water pipe, a heating pipe or a metal frame. Install a new airbag unit in the vehicle as soon as the unit is removed from the packaging. If the work is interrupted, place the airbag unit back in its packaging. Do not leave an undeployed airbag unit unattended if work is interrupted. Always place an airbag unit that has been removed from its packaging with the padded side facing upward.

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12/7/2004

Airbag

Page 3 of 15 69-24

CAUTION! Airbag units which have dropped onto a hard surface or show signs of damage must not be installed in the vehicle. Airbag units which have not been activated should be marked and returned to the manufacturer for disposal (use airbag unit transport container). Airbag units that have not been activated should be marked and sent back to the Warranty Test Center for disposal. (use airbag unit parts container for shipping). Always replace any airbag system component that has been mechanically damaged (example: dented or cracked). The storage and transportation of airbag units must comply with the regulations for explosive substances. Only install original seat covers that have been authorized for use with side airbags (recognizable by AIRBAG label). Do not install commercially available loose fitting seat covers. When installing a backrest cover ensure that the cover seam is straight in the area of the side airbag. Replace all seat cover clips. Only use original seat cover clips. For safety reasons always replace the seat cover if it is damaged in area of the side airbag, e.g. torn, burn holes, etc. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.BD01.69.4

12/7/2004

Airbag

Page 4 of 15 69-25

Airbag units, replacing after an accident. Accident with activated airbag The following must be replaced: All activated airbag units with control modules and sensors. Support for passenger's airbag. Airbag Spiral Spring -F138-. All safety belts with activated belt tensioners. If necessary, replace all other components that show visual damage. Accident without activated airbag If the Airbag MIL -K75- does not indicate a malfunction, no replacement of an airbag is necessary. Check safety belts separately. After replacing airbag units or control module, affix stickers (only tear-off strips) to the registration card and return registration card to the Warranty Test Center for registration. Registration card 000 010 227 C must be ordered separately.

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12/7/2004

Airbag

Page 5 of 15 69-26

Driver's airbag unit, removing and installing WARNING! Observe all safety precautions before starting work on any part of airbag system page 69-23 1 - Steering wheel 2 - Airbag unit connector 3 - Airbag unit 4 - 50 Nm (37 ft lb) 5 - Socket-head bolt 6.5 Nm (57 in. lb) Always replace 6 - Lower trim 7 - Foam tube 8 - Connector 9 - Airbag Spiral Spring F138-

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12/7/2004

Airbag

Page 6 of 15 69-27

CAUTION! Obtain radio anti-theft code. Before working on the electrical system, disconnect battery ground cable. Removing Notes: Before disconnecting radio, obtain anti-theft code. After reconnecting the battery, reconnect and adjust radio, clock, and power windows according to repair manual or owner's manual instructions. - Disconnect battery ground cable. - Place steering wheel -1- in straight ahead position (wheels in straight ahead position).

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12/7/2004

Airbag

Page 7 of 15 69-28

- Remove socket-head bolts 5-. Remove airbag unit -3from steering wheel and disconnect red connector -2from airbag unit. Installing Installation is in reverse order of removal. - Switch ignition on. CAUTION! Be sure no person remains inside the vehicle. - Reconnect battery ground cable.

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12/7/2004

Airbag

Page 8 of 15 69-29

Steering wheel, removing and installing Driver's side airbag unit is removed. - Remove lower trim -6- for steering column switch. - Remove foam tube -7- for connector -8- and disconnect connector. - Remove nut -4- and pull off steering wheel from steering column. Nut 50 Nm (37 ft lb) Airbag Spiral Spring -F138- -9remains on steering wheel.

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12/7/2004

Airbag

Page 9 of 15 69-30

Airbag Spiral Spring -F138-, removing and installing Driver's airbag unit and steering wheel removed. - Disconnect connector for horn. - Remove screws -1- and remove Airbag Spiral Spring -2- from steering wheel. Notes: Removing and installing of the Airbag Spiral Spring must be performed with front wheels in straight-ahead position. A new Airbag Spiral Spring is secured in center position with a tie wrap.

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12/7/2004

Airbag

Page 10 of 15 69-31

Passenger's side airbag unit, removing and installing 1 - Airbag unit Removing 32

Page 69-

2 - Screws 1.5 Nm (13 in. lb) 3 - Screws 1.5 Nm (13 in. lb) 4 - Cable clip 5 - Retaining tabs (4x) 6 - Retaining frame Removing 34

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Page 69-

12/7/2004

Airbag

Page 11 of 15 69-32

CAUTION! Obtain radio anti-theft code. Before working on the electrical system, disconnect battery ground cable. Removing Notes: Before disconnecting radio, obtain anti-theft code. After reconnecting the battery reconnect and adjust radio, clock, and power windows according to repair manual or owner's manual instructions. - Disconnect battery ground cable.

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12/7/2004

Airbag

Page 12 of 15 69-33

- Remove passenger's side storage shelf. - Remove screws -2- and -3-. - Tilt airbag unit from instrument panel and remove from retaining tabs 5-. - Unclip connector from bracket -4-and disconnect. Installing Installation is in reverse order of removal. - Switch ignition on. CAUTION! Be sure no person remains in the inside of the vehicle. - Connect battery ground cable.

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12/7/2004

Airbag

Page 13 of 15 69-34

Retaining frame, removing - Remove screws -1-. - Remove retaining frame -2-.

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12/7/2004

Airbag

Page 14 of 15 69-35

Airbag Control Module -J234-, removing and installing Note: Before removing the control module disconnect the battery ground cable. - Remove center console

Page 70-8 .

- Remove footwell air outlet Repair Manual, Heating & Air Conditioning, Repair Group 80 . - If necessary, cut carpet and dampening material in area of bracket for control module. - Move retaining clip -2- in direction of arrow and remove connector -3- from control module. - Remove nuts -4- and pull control module and bracket off of threaded stud. Nut -4- = 20 Nm (15 ft lb).

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12/7/2004

Airbag

Page 15 of 15 69-36

Airbag units, deploying (disposal) WARNING! DO NOT ignite airbag units in vehicles. According to regulations, airbag units must be rendered unusable by igniting them electrically before scrapping the vehicle. This is necessary because the airbag unit is a pyrotechnic device that may cause injuries if activated in an improper manner (e.g. using a cutting torch). - Remove airbag unit

Page 69-26

Use J-44210 Deployment Fixture and refer to the Airbag & Pyrotechnic Deployment Device Instruction Booklet for proper deployment procedure.

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12/7/2004

Instrument panel, removing and installing

Page 1 of 14 70-1

Instrument panel, removing and installing WARNING! Before working on the electrical system, disconnect the battery ground cable. Removing Note: Before disconnecting the battery, obtain radio anti-theft code. - Remove battery ground cable. - Remove radio. - Remove driver's side airbag unit, 26 .

Page 69-

- Remove passenger's side airbag unit, 69-31 . - Remove kneebar,

Page

Page 70-5 .

- Remove center console,

Page 70-8 .

- Remove driver's side storage shelf, 11 .

Page 70-

- Remove passenger's side storage shelf, 70-11 .

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Page

12/7/2004

Instrument panel, removing and installing

Page 2 of 14 70-2

- Remove heater control panel -3- and remove screws -2- from instrument panel. - Press control panel -1- with attached cables below instrument panel.

- Drill out shear bolts of steering column and lower steering column. - Disconnect harness connector -1-. - Disconnect ground wires at left and right instrument panel -2-. - Only remove connectors at central electric -3- that are attached to instrument panel wiring harness. Note: Do not open retainers of instrument panel wiring harness.

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12/7/2004

Instrument panel, removing and installing

Page 3 of 14 70-3

- Remove cover caps and remove screws. - Pull out clip retainers -1- at air intake housing. - Remove front screws on supports, loosen rear screws and fold back supports. - Carefully remove instrument panel. Installing - Disengage speedometer drive in plenum chamber (speedometer drive cable is only pushed into instrument). - Push instrument panel with retaining pins -2- into mounting brackets -3-. - Check seating of air ducts at heater housing. - Install speedometer drive cable. Repair Manual, Electrical System; Repair Group 90

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12/7/2004

Instrument panel, removing and installing

Page 4 of 14 70-4

Notes: After re-connecting the battery be sure to adjust radio, clock and power windows according to instructions in the repair manual or owner's manual. If the Airbag MIL -K75- comes on, erase DTC memory using Scan Tool VAG1551 and check DTC memory again.

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12/7/2004

Instrument panel, removing and installing

Page 5 of 14 70-5

Knee bar, removing 1 - Left bracket To remove, remover A-pillar trim. Pull bracket down from A-pillar. 2 - Bolt 10 Nm (7 ft lb) When installing, tighten bottom bolt first, then top bolt. 3 - Right bracket Remove same way as left bracket. 4 - Screw 10 Nm (7 ft lb) 5 - Trim Unclip at right angle.

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12/7/2004

Instrument panel, removing and installing

Page 6 of 14 70-6

6 - Right knee bar To remove, remove left knee bar and lower trim of A-pillar. Pull out knee bar to right from behind center console. 7 - Cap Pry out. 8 - Screw 10 Nm (7 ft lb) 9 - Left knee bar To remove, remove lower trim of A-pillar. Pull out knee bar to left from behind center console.

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12/7/2004

Instrument panel, removing and installing

Page 7 of 14 70-7

Note: When installing knee bar be sure that wiring close to the ignition lock and steering column is properly routed. 10 - Self-tapping screw 11 - Screw 10 Nm (7 ft lb) 12 - Trim Unclip at right angle.

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12/7/2004

Instrument panel, removing and installing

Page 8 of 14 70-8

Center console, removing and installing Removing - Remove parking brake grip and trim for lever Page 70-9 . - Remove extension for center console Page 7010 . - Remove bolts -1- and screws -2- (left and right). - Slightly lift console at rear and remove toward rear. - Disconnect electrical connectors. Installing - Install spacer sleeves -3- on threaded studs. - Install center console with retaining pins -4- into instrument panel.

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12/7/2004

Instrument panel, removing and installing

Page 9 of 14 70-9

Parking brake lever grip and trim, removing. - Pull up parking brake lever. - Push down locking lug arrow- with screwdriver. - Pull off grip and trim -1- from lever. - Pull trim -2- off parking brake lever.

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12/7/2004

Instrument panel, removing and installing

Page 10 of 14 70-10

Center console extension, removing and installing Removing - Unclip cover for gear shift lever and remove upward. - 1 = Manual transmission - 2 = Automatic transmission - Remove ash tray and remove screws. - Disconnect ash tray light. - Press down locking lugs -3and remove console toward rear. Installing - Push console with guide -4onto stud -5-.

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Instrument panel, removing and installing

Page 11 of 14 70-11

Storage shelf, driver's side, removing and installing Removing - Turn closure -1- 90

and unclip shelf -2-.

- Remove screws and remove shelf by tilting downward. Installing - Insert shelf first with stud -3- into instrument panel and fasten with screws to instrument panel. - Install trim -4- to stop into storage shelf. - Fasten trim and storage shelf to A-pillar with screws.

Storage shelf, passenger's side, removing - Remove screws and remove shelf by tilting downward. Observe pin -1-. Depending on the vehicle, the storage shelf may be provided with or without a cover.

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Instrument panel, removing and installing

Page 12 of 14 70-12

Glove box, removing - Remove passenger's side storage shelf Page 7011 . - Pull out vent insert -1-. - Remove screw and remove vent -2-. - Remove screws and remove glove box from instrument panel. - Unclip glove box light.

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Instrument panel, removing and installing

Page 13 of 14 70-13

Glove box lock 1 - Hinge pin Inserted from outside toward center First remove storage shelf, passenger's side. 2 - Stop To remove, remove lid and disassemble. 3 - Lock Removing remove lid and remove mechanism Observe lugs. 4 - Glove box lid, outer part Remove only together with inner part. Removing push out hinge pins.

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Instrument panel, removing and installing

Page 14 of 14 70-14

5 - Mechanism Removing disassemble lid. 6 - Lock cylinder Removing disassemble mechanism - Disassemble mechanism. - Carefully saw off lugs of mechanism. (Mechanism must be replaced. To retrofit lock cylinder, remove cover and press in lock cylinder. 7 - Cap To remove, remove mechanism and disassemble. Saw off end piece of cap. 8 - Locking bar Moves in elongated hole. 9 - Lid, inner part Remove only together with outer part.

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Door trim

Page 1 of 19 70-15

Door trim Special tools and equipment VAG1628 cartridge holder

3356 roller Pin 3 mm dia. Adhesive sealer D 469 101 A3 (cartridge)

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Door trim

Page 2 of 19 70-16

Front door trim 1 - Trim cover Location for exterior Mirror Adjustment Switch -E43- or for manual mirror adjustment. 2 - Cover Clipped into door pull. 3 - Door pull 4 - Screw 5 - Screw 6 - Trim cover Remove from door frame at right angles. Support with pry bar 80-200.

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Door trim

Page 3 of 19 70-17

7 - Screw 8 - Locking knob Remove from locking rod. 9 - Trim plate After removing trim, unscrew locking knob 8 - from locking rod and remove trim plate. 10 - Trim clip To remove: Drive out spreader pin. 11 - Retaining bracket Push pin out to remove. 12 - Screw 13 - Trim Removing and installing Page 7019

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Door trim

Page 4 of 19 70-18

14 - Rubber inlay 15 - Front door tray Secured by screws through rear of trim. 16 - Speaker cover Fastened with clips from the rear of trim. 17 - Window crank Removing and Installing Page 7019 Installation position when window is closed: 45 12

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Door trim

Page 5 of 19 70-19

Front door trim, removing and installing Removing - Remove mirror adjustment knob -1-. Note: Illustration shows electric mirror adjustment. Manual mirror adjustment Page 66-11 .

- Carefully pry out cover from door pull -2-.

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Door trim

Page 6 of 19 70-20

Vehicles with power windows or electrically adjustable mirror - Disconnect connector -1- for power mirror switch E40- or -E 41- and if necessary connector -2- for mirror adjustment switch -E43-.

Vehicles with mechanical window crank - Unclip in direction of arrow. - Remove screw -1- with serrated washer. - Pull off crank. - Remove sleeve -2- (only front doors). Note: Installation position with closed window: 45

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Door trim

Page 7 of 19 70-21

Continued for all vehicles - Remove screws -1-.

- Remove screws -1- and -2- at front and rear edge of door trim.

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Door trim

Page 8 of 19 70-22

- Pull out door trim -1- upward from window slot seal -arrow-. Note: If it is difficult to remove the door trim close to trim -2-, also remove this trim.

- Disconnect connector -1- for Warning Light for Anti-theft Immobilizer sensor -K117- (only driver's side). - Lift door trim out of retainer brackets. Installing Installation is in reverse order of removal.

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Door trim

Page 9 of 19 70-23

Rear door trim 1 - Cover Position for treble speaker. 2 - Trim cover Clipped into door pull. 3 - Door pull 4 - Screw 5 - Screw 6 - Locking knob Remove from locking rod. 7 - Trim plate After removal of door trim, unscrew locking knob - 6 - from lock rod and remove trim plate.

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Door trim

Page 10 of 19 70-24

8 - Screw 9 - Door trim Removing and installing Page 7026 . 10 - Trim cover Remove from door frame at right angle. Support with pry bar 80-200. 11 - Trim clip Push pin out to remove. 12 - Screw 13 - Screw 14 - Retaining bracket Push pin out to remove.

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Door trim

Page 11 of 19 70-25

15 - Rubber inlay 16 - Rear door tray Secured by screws from rear of door trim. 17 - Speaker grille Secured by clips from rear of door trim. 18 - Window crank Removing and installing Page 7027 . Installation position with window closed: 45 12

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Door trim

Page 12 of 19 70-26

Rear door trim, removing and installing Removing - Pry out cover -1- from door handle -2-.

Vehicles with power windows - Disconnect connector -1- for window switch -E52or -E54- and, if necessary, connector for treble speaker -R14- or -R15-.

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Door trim

Page 13 of 19 70-27

Vehicles with mechanical window winders - Unclip cover in direction of arrow. - Remove screw -1- with serrated washer. - Pull off window crank. Note: Installation position with window closed 45

12 .

All vehicles - Remove screws -1-.

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Door trim

Page 14 of 19 70-28

- Remove screws -1- and -2- at front and rear edge door trim.

- Remove door trim from top of window slot seal arrow- and then lift out of retaining brackets at bottom. Installing Install in reverse order of removal.

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Door trim

Page 15 of 19 70-29

Door moisture barrier, removing and installing The door moisture barrier is designed to protect and seal the vehicle interior against noise, water entry and drafts. Moisture barrier foil can be removed and reinstalled up to 4 times without the need of additional adhesive, providing that the foil is not damaged. Replacement parts for moisture barrier foil with adhesive are provided up to 02.95. Replacement parts for moisture barrier foil without adhesive are provided from 03.95. For replacement parts use adhesive D 469 101 A3. Adhesive area is shown as the hatched area in the illustration.

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Door trim

Page 16 of 19 70-30

Removing - Remove door trim 26 .

Page 70-19 or

Page 70-

- Remove securing tab from opening in door. - Remove interior door handle by pushing in driving direction and disengage pull rod -1-.

- Remove screws (arrows). Remove door loudspeaker with frame and disconnect connector.

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Door trim

Page 17 of 19 70-31

- Remove clips -1- for retainers and trim clips by pushing pins with a drift approx. 3 mm in diameter toward inside and remove retainers -2-. Notes: Check clips and retainers for damage, replace if necessary. Remove spreader pins and retainers from inside of door after removing moisture barrier.

- Remove moisture barrier foil all around gradually step by step (about 15 cm per step). Grasp foil close to hatched area if possible.

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Door trim

Page 18 of 19 70-32

Installing - When replacing foil, remove remaining adhesive on door -2-. Remove some of old adhesive, form a ball and use it to dab off remaining adhesive. Replacement moisture barrier foil up to 02.95 - Guide electrical wiring for door components (window motor, loudspeaker and seat adjusters) through foil and remove protective strip from adhesive. - Adjust foil according to openings for securing clips and press on. - Press on moisture barrier foil in adhesive area (hatched area) -1- to door all around using roller 3356. - Check for firm adhesion especially at lower section of door.

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Door trim

Page 19 of 19 70-33

Replacement moisture barrier foil from 03.95 - Using cartridge gun VAG1628, apply adhesive D 469 101 A3 (adhesive bead about 5mm dia.) all around on foil -1- (hatched area). - Guide electrical wiring for door components through foil (window motor, loudspeaker and seat adjusters). - Adjust foil according to openings for securing clips and press on.

- Press on moisture barrier foil in adhesive area (hatched area) -1- to door all around using roller 3356. - Check for firm adhesion especially at lower section of door.

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Trim

Page 1 of 28 70-34

Trim Upper A-pillar trim, removing and installing Note: The trim fits over sealing flange of door seal section, see section A-A. 1 - Retaining clip 2 - Cover cap Pry out. 3 - Screw 4 - Trim To remove, first remove upper trim of B-pillar. Removing - Remove grab handle -8- and pry out cover -2-. - Remove screws -3and -6-. - Starting at rear, pull off clips parallel to sealing flange.

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Trim

Page 2 of 28 70-35

5 - Spreader nut 6 - Screw 7 - Cover cap Part of grab handle - 8 -. 8 - Grab handle To remove: - Fold grab handle down. - With a screwdriver pry out cover - 7 -, remove screws - 9 and remove grab handle. 9 - Screw 10 - Clip Pushed into A-pillar mounting point.

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Trim

Page 3 of 28 70-36

Lower A-pillar trim, removing and installing Note: To remove lower trim panel (right or left), remove inner sill Page 70-61 . panel trim 1 - Right trim Removing - Remove screw. - Remove trim from retaining clip. - Pull out from clip. Trim can be pulled out from under A-pillar trim. Installing: Position trim under upper trim of A-pillar, guide into clamp and press pins into retaining clip. To make installation of pins into retaining clips easier, remove screw for lower storage tray. Check for correct seating of of trim on door inner seal.

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Trim

Page 4 of 28 70-37

2 - Spring clip Inserted into A-pillar. 3 - Clip If clipped too tightly in trim, open clip slightly with screwdriver. Inserted into A-pillar. 4 - Left trim Removing - Remove hood release and disengage cable. - Remove screw, pull out trim from spring clip, then pull out from clip. Trim can be pulled out from under upper Apillar trim. Installing: Place under upper Apillar trim, guide into clip and press pins into retaining spring clip. To make installation of pins into retaining clips easier, remove screw for lower storage tray. Check for correct seating of of trim on door inner seal.

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Trim

Page 5 of 28 70-38

B-pillar trim, removing and installing Note: The trim fits over sealing flange of door seal section, see section A-A. 1 - Retaining pin Engages in roof frame. 2 - Upper trim Removing Remove relay fitting (40 Nm). Pull out trim from upper spring clip. Note: locking lugs at top, they engage behind A-pillar trim and C-pillar trim. Installing: Locate upper retaining pins in roof frame and push trim panel up until lower retaining lugs grip trim panel. Press upper retaining lugs behind trim. Press trim over sealing flange.

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Trim

Page 6 of 28 70-39

3 - Operating button Pull off from height adjustment mechanism. 4 - Spring retaining clip 5 - Lower trim To remove, remove inner sill panel cover Page 70-61 Remove front fitting 40 Nm (30 ft lb)

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12/7/2004

Trim

Page 7 of 28 70-40

Upper C-pillar trim, removing and installing Notes: The trim fits over sealing flange of door seal section, see section A-A. Illustration shows Sedan, for Wagon there is an additional clip in the roof frame. 1 - Trim To remove, first remove upper trim for B-pillar and cover of inertia reel for safety belt. Also loosen trim for D-pillar. Removing - Remove grab handle -5-. - Pry out cover cap -2. - Remove screws -3and -10-. - Pull lower side of trim down and remove from seal flange and clips -8-. Installing: Press over sealing flange and then push into clips.

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Trim

Page 8 of 28 70-41

2 - Cover cap Pry out. 3 - Screw 4 - Retaining clip 5 - Grab handle Removing - Fold grab handle down. - With screwdriver pry out cover -7-. - Remove screws -6and remove grab handle.

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Trim

Page 9 of 28 70-42

6 - Screw 7 - Cap Part of grab handle - 5 8 - Clip Disengage in opposite direction of arrow. 9 - Coat hook Clipped into trim. 10 - Screw

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Trim

Page 10 of 28 70-43

Lower C-pillar trim, removing and installing Note: The trim fits over sealing flange of door seal section, see section A-A.. 1 - Trim Removing - Remove upholstery Page 70-45 and seat belt cover Page 70-48 . - Loosen lower screw of upper C-pillar trim. - Loosen sill trim in rear section from clips and pull up. - Remove screws - 2 and plastic nut - 4 -. - Pull off trim from below and up from sealing flange and remove from under C-pillar trim.

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Trim

Page 11 of 28 70-44

2 - Screw 3 - Safety belt opening Slotted 4 - Plastic nut 5 - Cover Only for vehicles without additional upholstery. Unclip. 6 - Clip

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12/7/2004

Trim

Page 12 of 28 70-45

Lower C-pillar upholstery, removing and installing 1 - Upholstery To remove, unhook upholstery on top, pull off lower C-pillar trim and unclip lower section. 2 - Clip 3 - Velcro strip 4 - Screw 5 - Insert 6 - Tongue

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Trim

Page 13 of 28 70-46

D-pillar trim (Sedan), removing and installing 1 - Cover cap 2 - Trim Removing Remove screws and pull out from spring clips. 3 - Spring clip 4 - Retaining pin

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12/7/2004

Trim

Page 14 of 28 70-47

D-pillar trim, removing and installing (Wagon) 1 - Cover cap 2 - Trim Removing Remove screws, starting from front pull out of clips and spring clips. 3 - Clip 4 - Retaining clip 5 - Spring clip 6 - Retaining pin

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Trim

Page 15 of 28 70-48

Rear shelf and belt retractor cover, removing and installing (Sedan) 1 - Belt guide Removing 50

Page 70-

Installing: install on belt retractor. 2 - Cover for belt retractor Removing Remove screw and lift out cover upward. Note retaining clips and retaining pins. For vehicles with upholstered C-pillar trim, removing Page 70-45 Installing: Position locking lugs of rear shelf and retaining clips and press down.

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Trim

Page 16 of 28 70-49

3 - Retaining lugs Clip into rear shelf panel 4 - Rear shelf To remove, first remove covers for belt retractors. Removing Unclip rear shelf panel upward and lift out of retaining lugs. Installing: Insert rear shelf panel with retaining lugs into retaining pockets and clip at front. 5 - Retaining lugs 6 - Retaining pockets 7 - Clip 8 - Retaining clip Installed on flange (side window).

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Trim

Page 17 of 28 70-50

Belt guide, removing - Insert screwdriver between belt guide -1- and cover for belt retractor -2- into removal hole for belt retractor. - Pry off belt guide -1- from belt retractor by twisting screwdriver.

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12/7/2004

Trim

Page 18 of 28 70-51

Front luggage compartment trim and belt retractor cover, removing and installing (Wagon) Note: The trim fits over sealing flange of door seal section, see section A-A.. 1 - Trim Removing - Remove belt retractor cover, rear luggage compartment trim and backrest. - Loosen lower screw on C-pillar trim. - Lift inner sill panel trim at rear by disengaging clips.

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Trim

Page 19 of 28 70-52

2 - Felt strip 3 - Belt retractor cover Removing belt guide Page 70-50 If installed, remove lower C-pillar upholstery Page 7045 4 - Retaining clip Installed on flange (side window). 5 - Nut 6 - Plug 7 - Plastic nut 8 - Cover Unclip.

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12/7/2004

Trim

Page 20 of 28 70-53

Rear luggage compartment trim, removing and installing (Wagon) 1 - Cover 2 - Trim To remove, remove belt retractor cover. On vehicles with luggage compartment cover, pull cover off guide rails and then remove applicable guide rail. Rear luggage compartment trim is installed on front luggage compartment trim. See sectional view. 3 - Nut 4 - Retaining clip Installed on flange (side window).

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12/7/2004

Trim

Page 21 of 28 70-54

Luggage compartment side trim, (Sedan) 1 - Trim Removing - Remove rear bench seat Page 72-32 . Remove storage box and pry out plugs. - Remove lower part of C-pillar trim Page 70-56 . 2 - Storage box Removing Remove screws, press carpet support - 3 - toward rear and release locking lug - 4 -. 3 - Carpet support 4 - Locking lug Release from above using screwdriver.

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Trim

Page 22 of 28 70-55

5 - Warning triangle retaining bracket 6 - Plug Pry out using special tool 80-200. 7 - Tab Installation position Attaching rear trim Page 70-56 . 8 - Mounting hole Installation position Attaching rear trim, Page 70-56 . 9 - Velcro strip Installation position Attaching rear trim Page 70-56 .

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Trim

Page 23 of 28 70-56

Trim, removing - Unclip inner sill cover at rear and pull up 70-61 .

Page

- Remove cover cap -1- and remove nut under it. - Remove plug -2- and lift floor covering. - Slightly lift up C-pillar trim at floor and pull out luggage compartment trim -4-.

Rear trim, attaching 1 - Velcro strip 2 - Metal lug 3 - Plug-in tab

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12/7/2004

Trim

Page 24 of 28 70-57

Rear lock carrier trim, removing (Sedan) 1 - Lock carrier trim Removing - Remove plugs -5and nuts -4-. - Pry out trim at top from spring lugs -2and unclip. 2 - Spring retaining clip 3 - Clip Six clips. 4 - Plastic nut 5 - Plug

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Trim

Page 25 of 28 70-58

Rear lock carrier trim, removing (Wagon) 1 - Lock carrier trim Removing - Unclip left and right trim and remove side tabs. - Tilts cover froward and unclip together with center clip upward. 2 - Clip Five clips.

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Trim

Page 26 of 28 70-59

Tailgate trim, removing and installing (Wagon) 1 - Clip Removing Turn clip 45 remove.

and

2 - Spreader clip Remove spreader pin. 3 - Spreader nut 4 - Self-tapping screw 5 - Cover 6 - Cover 7 - Retaining lugs 8 - Cover 9 - Self-tapping screw

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Trim

Page 27 of 28 70-60

Tailgate hinge cover cap, removing and installing (Wagon) - Pry out plug -2- with screwdriver. - Remove cap -1- from hinge (slotted on top).

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Trim

Page 28 of 28 70-61

Sill cover, removing and installing 1 - Sill cover Removing Press down, unclip and pull up from clip. Installing: Check position of sill cover at door seals. 2 - Clip 3 - Retainer 4 - Door inner seal

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12/7/2004

Headliner

Page 1 of 13 70-62

Headliner Molded headliner, removing and installing (Sedan) Removing - Remove trim of A-pillar, B-pillar, upper C-pillar and D-pillar. - Remove interior light. - Remove sun visors -2-. With illuminated mirrors also disconnect connector in roof frame. - Remove screw from mounting bracket -1- , turn 90 and remove from roof frame.

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Headliner

Page 2 of 13 70-63

- Pull end strip -4- (clipped on) and pull down from roof frame. - Remove clips -5- from roof frame. - Turn down passenger's seatback and remove headliner dioganally through right rear door opening. Installing - Check foam strip -1- for good adhesion on roof, reglue if necessary. - Align headliner at front with sunvisor mountings -6- and at rear using center marking -3- and indentation -2-.

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Headliner

Page 3 of 13 70-64

- Fasten headliner at front with sun visors. - Insert clips -5-. Clips will hold headliner in position. - Press in end strip -4- in roof frame. - Install all other components.

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12/7/2004

Headliner

Page 4 of 13 70-65

Molded headliner with sunroof, removing and installing (Sedan) Removing - Remove trim for A-pillar, B-pillar, upper C-pillar and D-pillar. - Remove interior light. - Remove cover for sunroof drive. - With sunroof open, remove weather strip around sunroof opening.

- Remove sunvisors -2-. With illuminated mirrors also disconnect connector in roof frame. - Remove screw from mounting bracket -1- , turn 90 and remove from roof frame.

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Headliner

Page 5 of 13 70-66

- Pull end strip -3- (clipped on) and pull down from roof frame. - Remove clips -4- for trim from roof frame. - Turn down passenger's seatback and remove headliner diagonally through right rear door opening. Installing - Check foam strip -2- for good adhesion on roof and re-glue if necessary using adhesive D 001 200. - Align front of headliner with sunvisor mountings and front sunroof opening. - Insert clips -4-. Clips hold headliner in position. - Install all other components.

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Headliner

Page 6 of 13 70-67

Headliner, removing and installing (Wagon) Note: To remove, first remove trim for A-pillar, B-pillar, C-pillar , Dpillar, sun visors and interior light. 1 - Foam strip Check for firm adhesion and re-glue if necessary with adhesive D 001 200. 2 - Center marking in roof frame (indentation) 3 - Center marking in headliner (notch) 4 - End strip Clipped into roof frame.

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Headliner

Page 7 of 13 70-68

5 - Headliner Removing Unclip end strip - 4 -, remove trim clips - 6 from roof frame. Installing: - Position headliner and insert trim clips 6 -. - Align headliner at front with sun visor mountings, at rear using center markings - 2 - and 3-. - Secure front of headliner with sun visors. 6 - Trim clip Holds headliner in position.

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Headliner

Page 8 of 13 70-69

Headliner with sunroof, removing and installing (Wagon) Removing - Remove trim for A-pillar, B-pillar, upper C-pillar and D-pillar. - Remove interior light. - Remove cover for sunroof drive. - With sunroof open, remove weather strip around sunroof opening.

- Remove sun visors -2-. If equipped with illuminated mirrors also disconnect electrical connectors. - Remove support -1-, turn 90 roof frame.

and remove from

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Headliner

Page 9 of 13 70-70

- Pull down end strip -2(clipped on) from roof frame. - Remove clips -4- for trim from roof frame. Installing - Check foam strip -1- on roof for good adhesion and if necessary glue on with adhesive D 001 200. - Align headliner -3- at front with mountings for sun visor and front edge of sunroof opening. - Install clips -4-. Clips hold headliner in position. - Install all other components.

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Headliner

Page 10 of 13 70-71

Roof dampening / reinforcement, removing and installing Notes: The function of roof reinforcement and dampening is accomplished by material glued to the roof. For sheet metal work on the roof, the dampening/reinforcement material can be cut out. The cut-out area must not be larger than 1000 cm2 155 in.2 (example: 40 cm x 25 cm or 15.5 in. x 9.8 in.). The cut-out area must be replaced after completion of the repair. If the cut-out area must be larger than 1000 cm2 across or lengthwise through the dampening/ reinforcement material, then the entire material must be replaced. Required tools: Carpet roller, approx. 150 to 200 mm wide Notched putty knife (tooth height 2 to 3 mm) Carpet utility knife Hot air gun

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Headliner

Page 11 of 13 70-72

Required materials: Adhesive D 190 MKD A3 Removing - Make cuts in dampening/reinforcement material across roof. - Cut material in approx. 100 mm wide strips in lengthwise direction. - Pull off strips one by one from roof, starting in center and proceeding to outside. Support roof with one hand while pulling. CAUTION! If the paint is damaged when cutting with the utility knife, it is important that the damaged area is protected against corrosion using primer ALN 002 003 04. The remaining paper sticking to the roof can be removed easily with a heat gun. Small pieces of the paper can be removed with a scraper. Small remaining residue does not need to be removed. CAUTION! Do not use heat gun temperature higher than 100 C (212 F) or the paint will be damaged.

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Headliner

Page 12 of 13 70-73

Installing - Apply adhesive to dampening/reinforcement material and spread with commercially available notched scraper. The adhesive temperature must not be below 20 C (68 F). - Clean excess adhesive immediately with water. Partly cured adhesive can be cleaned with spot remover (ethylacetate, etc.). Completely cured adhesive cannot be removed. - Let adhesive flash off at 20 C (68 F) for about 30 minutes. Finger test: adhesive must no longer pull strings. - If work is interrupted for some reason, scrape adhesive off immediately. That way material can be used again. - Immediately before glueing, heat adhesive with a heat gun at about 60 C (140 F) for 2 to 3 minutes. Distance of heat gun nozzle from adhesive should be 200 to 300 mm (8 to 12 in.). - Position and center dampening / reinforcing material. - Starting from rear, roll on material over entire area.

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Headliner

Page 13 of 13 70-74

Sedan a

55 mm (2.1 in.)

1 - Dampening / reinforcing material 2 - Roof frame, rear

Wagon b

43 mm (1.69 in.)

1 - Dampening / reinforcing material 2 - Roof frame, rear

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Front seat

Page 1 of 31 72-1

Front seat Front seat, removing - Slide seat forward. - Unclip cover strip -1- from seat rail and take out rearward and up. - Remove cover at rear of opposite seat rail.

- Press clip -1- together and remove (arrow). - Disconnect connector for heated seat (if so equipped). - Release locking rod and slide to rear out of seat rails. Note: If seat fore and aft movement is difficult or if there is excessive play, check the sliding pieces at the rear of the seat or front -2- and replace them if necessary.

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Front seat

Page 2 of 31 72-2

Seat and backrest frames, separating - Remove front seat

Page 72-1 .

Note: For seats with storage tray or deluxe seats, use the relevant detailed information describing standard or sport seats. Standard and sport seats, seat outer side A - Seat with height adjustment B - Seat without height adjustment - Press off adjustment knob -1-. - Drive left and right spreader pins -2- through to inside. Front spreader pin makes contact with seat frame. With screwdriver press pin from above downward. - Remove screw -3-. - Remove left and right lock washers. - Remove seatback frame from pin -5-. - Check bushings -6- (left and right) for damage and replace if necessary.

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Front seat

Page 3 of 31 72-3

- Replace screw -3- (lock screw). Remove locking fluid residue in nut thread with thread tap. Coat new screw with locking fluid D 185 400 A2. Standard and sport seat with storage shelf

- Press off adjustment knob-1-. - Remove screws and remove trim upward from bracket -2-. - Remove screw -3-. - Remove lock washer -4-. - Disassemble seat inner side. - Remove seat back frame from pin -5-.

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Front seat

Page 4 of 31 72-4

Deluxe seat - Press off adjustment knob -1-. - Drive spreader -2- out toward inside. - Pull off adjustment controls -3- and -4- after removing screws. - Remove screws -7-. - Remove storage shelf -5- with retainer -6- from seat frame. - Remove lock washer -8-. - Remove screw -9-. - Complete disassembly on inner side of seat. - Remove seat frame from pins on left and right sides.

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Front seat

Page 5 of 31 72-5

Seat frame (standard and sport seat) 1 - Operating lever 2 - Locking rod Lubricate with allpurpose grease. 3 - Spring 4 - Bushing 5 - Clip 6 - Thrust piece Press thrust piece into sliding plate and bend over tab. 7 - Sliding plate

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Front seat

Page 6 of 31 72-6

8 - Sliding piece 9 - Bolt 60 Nm (44 ft lb) 10 - Reinforcement plate 11 - Bolt 60 Nm (44 ft lb) On seats with height adjustment rivets are used instead of bolt. 12 - Screw 4 Nm (35 in. lb) Lock screw Always replace screw. Remove locking fluid residue in nut thread by using thread tap. Coat new screw with locking fluid D185 400 A2.

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Front seat

Page 7 of 31 72-7

13 - Bushing 14 - Hook tabs for upholstery 15 - Clip for upholstery 16 - Sliding piece Lubricate contact surface of seat frame with multi-purpose grease. 17 - Bushing bracket

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Front seat

Page 8 of 31 72-8

Seat frame with mechanical height adjustment 1 - Spring In seat pan frame. Retainer for height adjustment. Low seat height = high spring tension. 2 - Cable For seat height adjustment. Connected in front under seat pan. 3 - Mechanism for height adjustment 4 - Pressure piece Press into slide plate and bend over tab.

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Front seat

Page 9 of 31 72-9

5 - Clip 6 - Sliding piece 7 - Sliding plate Riveted to reinforcement plate. 8 - Reenforcement plate Riveted to sliding plate. 9 - Bolt 60 Nm (44 ft lb) 10 - Adjustment shaft for height adjustment 11 - Sub-frame

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Front seat

Page 10 of 31 72-10

12 - Screw 4 Nm (35 in. lb) Lock screw. Always replace screw. Remove locking fluid residue in nut thread by using thread chaser. Coat new screw with locking fluid D185 400 A2. 13 - Bushing 14 - Adjusting handle For height adjustment. Install during assembly. 15 - Adjusting handle For tilt adjustment. Install during assembly. 16 - Operating shaft for tilt adjustment

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Front seat

Page 11 of 31 72-11

17 - Shaft for tilt adjustment 18 - Sliding piece Lubricate contact area of seat frame with multi-purpose grease. 19 - Bushing 20 - Bushing clamp 21 - Operating lever 22 - Engagement rod Lubricate with multipurpose grease. 23 - Spring 24 - Spring Retainer for tilt adjustment. Attached between lower seat frame and shaft for tilt adjustment.

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Front seat

Page 12 of 31 72-12

Seat frame with mechanical height adjustment, disassembling and assembling - Adjust seat front to highest position. - Remove front seat

Page 72-1 .

- Separate seat frame and frame for back rest. Page 72-2 . Note: On heated seats, disconnect connectors for back rest heating from connector for seat heating and pull out cable from seat frame. - Remove cover and padding for front seat with height adjustment Page 74-5 . Lower frame, removing - Loosen clips for felt trim from seat pan. - Remove screws -2-, remove bushing clamp -3and spring -4- and remove operating rod -1- for seat fore and aft adjustment from bushing toward rear.

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Front seat

Page 13 of 31 72-13

- Adjust seat tilt so that springs -1- have lowest tension. - Disengage springs -1- at lower seat frame (arrows) and remove.

- Remove rear -1- (seat pan / lower frame). - Press lever -2- outward (arrows) and pull off from inside axle -3- of lower frame.

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Front seat

Page 14 of 31 72-14

- Remove spring -1- and circlip -2- on tilt mechanism.

- Remove lock washer -1- on seat outer side and push tilt adjustment shaft -2- toward inside and remove.

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Front seat

Page 15 of 31 72-15

- Remove bolts -1-on left side and -2- on right side (reverse order for right seat).

- Pry front mounting point -1- of tilt mechanism out (firm bushing with collar) and push shaft for tilt mechanism -2- parallel toward rear (arrows) until rear mounting point -3- is pushed out of guide.

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Front seat

Page 16 of 31 72-16

Note: If necessary, lightly tap with hammer to help parallel movement of the shaft for tilt mechanism. - Remove lower seat frame together with tilt mechanism. Cable for height adjustment, removing - Remove left and right springs -1- for height adjustment mechanism. - Bend holding tabs -2- for cable eyes -3- and remove cable eyes.

- Remove lock nut -1- for cable tensioning and remove threaded sleeve -2- in direction of arrow. - Pull off cable clamps at front and under seat pan.

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Front seat

Page 17 of 31 72-17

Cable, adjusting - Install complete cable including springs on height adjustment mechanism. - Adjust threaded sleeve -1- in such a way that locks -2- of height adjustment mechanism can be operated on both sides at same time. Height adjustment mechanism, removing

- Block lever -1- with suitable turnbuckle -2- (i.e. 3004) and keep under slight tension. Note: The turnbuckle takes up the spring tension (arrow) of the height adjustment mechanism during removal. The threaded bolts of the turnbuckle must have enough length for opening.

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Front seat

Page 18 of 31 72-18

- Remove clips -1- and press out bearing pins -2-. - Open turnbuckle to release tension. - Remove clip -3- and press out bearing pin -4-.

- Remove spring -1- from front bracket -2- in frame for seat pan and pull out lever including height adjustment mechanism and spring toward rear.

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Front seat

Page 19 of 31 72-19

Seat frame with electrical height adjustment 1 - Motor for Height Adjustment -V30- or V332 - Spring In frame for seat pan. Retainer for height adjustment. Low seat height = high spring tension. 3 - Adjustment spindle For seat height adjustment. 4 - Height adjustment mechanism 5 - Pressure piece Press pressure piece into sliding plate and bend over tab.

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Front seat

Page 20 of 31 72-20

6 - Clip 7 - Sliding piece 8 - Sliding plate Riveted to reinforcement plate. 9 - Reinforcement plate Riveted to sliding plate. 10 - Bolt 60 Nm (44 ft lb) 11 - Height Adjustment Switch -E63- or -E6612 - Lower frame

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Front seat

Page 21 of 31 72-21

13 - Screw 4Nm (35 in. lb) Lock screw. Replace screw. Remove locking fluid residue in nut thread by using thread tap. Coat new screw with locking fluid D185 400 A2. 14 - Bushing 15 - Adjustment handle For height adjustment. 16 - Adjustment handle For tilt adjustment. Press on when installing. 17 - Operating shaft for tilt adjustment 18 - Tilt mechanism shaft

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Front seat

Page 22 of 31 72-22

19 - Sliding piece Lubricate contact surface of seat frame with multi-purpose grease. 20 - Bushing 21 - Bushing clamp 22 - Operating lever 23 - Engagement rod Lubricate with multipurpose grease. 24 - Spring 25 - Spring Retainer for tilt mechanism. Attached between lower frame and tilt mechanism shaft.

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Front seat

Page 23 of 31 72-23

Seat frame with electrical height adjustment, disassembling and assembling - Place front seat in highest position - Remove front seat

Page 72-1 .

- Separate seat frame and backrest 2.

Page 72-

Note: On heated seats, disconnect connectors for backrest heating from connector for seat heating and pull out cable from seat frame. - Remove cover and padding for front seat with height adjustment Page 74-5 . Lower frame, removing - Loosen clips for felt trim from seat pan. - Remove screws -2-, remove bushing clamp -3and spring -4- and remove operating rod -1- for seat fore and aft adjustment from bushing toward rear.

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Front seat

Page 24 of 31 72-24

- Adjust seat tilt until springs -1- have lowest possible tension. - Unhook springs -1- from lower seat frame (arrows) and remove.

- Disengage adjustment shaft from lower frame by removing circlips -1- and pins -2-. Notes: Seat must be in uppermost position. When installing be sure adjustment shaft is in same position.

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Front seat

Page 25 of 31 72-25

- Remove rear bolts -1- (seat pan / lower frame). - Press lever -2- outward (arrows) and pull off from inside axle -3- of lower frame.

- Remove spring -1- and circlip -2- from tilt mechanism.

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Front seat

Page 26 of 31 72-26

- Remove washer -1- on outer side of seat and push operating shaft for tilt mechanism -2- toward inside and remove.

- Remove bolts for tilt mechanism on left side -1and right side -2-.

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Front seat

Page 27 of 31 72-27

- Pry front mounting point -1- of tilt mechanism out (firm bushing with collar) and push shaft for tilt mechanism -2- parallel toward rear (arrows) until rear mounting point -3- is pushed out of guide. Note: If necessary lightly tap with hammer to help parallel movement of the shaft for tilt mechanism. - Remove lower frame with tilt mechanism. Height adjustment mechanism, removing - Block lever -1- with suitable turnbuckle -2- (i.e. 3004) and keep under slight tension. Note: The turnbuckle takes up spring tension (arrow) of the height adjustment mechanism during removal. The threaded bolts of the turnbuckle must have enough length for opening.

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Front seat

Page 28 of 31 72-28

- Remove clips -1- and press out bearing pins -2-. - Open turnbuckle until spring tension is released. - Remove clip -3- and press out bearing pin -4-.

- Disengage spring -1- at front bracket -2- in seat pan frame and pull out lever (including height adjustment mechanism) together with spring toward rear.

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Front seat

Page 29 of 31 72-29

Motor for Height Adjustment -V30- or -V33and adjustment shaft, removing and installing Note: To remove the motor for height adjustment it is not necessary to remove the adjustment shafts. - Remove spring washer -1- and pull out shaft -3from mountings on seat pan frame. - Pull out adjustment shaft with gear box -2- from mounting and pull off of flexible shaft -4-. - Remove connector for height adjustment motor V30- or -V33-.

- Remove bolts for motor (from seat) and lift out motor -1- between flexible shafts -2- (arrow).

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Front seat

Page 30 of 31 72-30

Backrest frame 1 - Protective strip Glue on with adhesive D 001 200. 2 - Bolt 5 Nm (44 in. lb) 3 - Washer 4 - Adjustment knob 5 - Connecting tab 6 - Support (sport seat only) 7 - Locking hook Optional equipment only , otherwise like item - 5 -. 8 - Backrest frame Replacing 31

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Page 72-

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Front seat

Page 31 of 31 72-31

Backrest frame, replacing Only sport seat backrests are supplied as replacement parts. If a standard backrest frame must be replaced, do the following: - Cut off support -1-. Angle grinder VAG1422/A is suitable for this work. - Remove burrs at cutting points (arrows) and protect against corrosion with primer ALN 002 003 04.

As replacement parts, backrests for both sides are are equipped with a backrest adjustment -1-. - Remove unneeded backrest adjustment with a screwdriver.

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Rear seats

Page 1 of 2 72-32

Rear seats Rear seat and split backrest, removing - Lift up seat bench with pull strap. - Remove socket head bolt -1- and remove seat bench part including hinges. - Fold down both backrest sections.

- Remove clips -1- from pins of adapter -2- at center mounting of backrest sections.

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Rear seats

Page 2 of 2 72-33

- Remove socket-head bolt -1- at applicable outer mount of backrest section. - Press down backrest section with mounting at a slant and disengage from support bracket -2-. - Pull out backrest section from center mounting and remove from vehicle.

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Seat upholstery

Page 1 of 23 74-1

Seat upholstery Cover and padding for front seat, removing and installing 1 - Upholstery wire Connected in padding, disconnect and connect with awl VAG1636. 2 - Cover Removing: - Separate seat and Page backrest 72-2 - Remove cover and padding Page 743 3 - Cover tensioning wire Secure cover with clips and attach to hook tabs, then pull tensioning wire tight and secure.

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Seat upholstery

Page 2 of 23 74-2

4 - Clip strips 5 - Padding Removing: - Separate seat and backrest Page 72-2 - Remove cover and Page 74padding 3 6 - Seat frame 7 - Cover hook tabs 8 - Clip

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Seat upholstery

Page 3 of 23 74-3

Cover and padding, removing - Unhook left and right tensioning wire -1-. Note: When clipping in, re-tension wire -1- slightly.

- Pry out clips -1- and open left and right tabs -2-.

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Seat upholstery

Page 4 of 23 74-4

- Unhook clip strips -1- from seat pan.

- Roll up seat cover until upholstery wires -1- are visible. - Unhook upholstery wire -1- with awl VAG1636 and remove cover. - Remove padding from seat frame. Note: To make it easier to install, warm cover to about 30 C (86 F).

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Seat upholstery

Page 5 of 23 74-5

Cushion cover and padding for front seat with height adjustment, removing and installing 1 - Upholstery wire Connected in padding, disconnect and connect with awl VAG1636. 2 - Cover Removing: - Separate seat and Page backrest 72-2 - Remove cover and padding Page 743 3 - Cover tensioning wire Secure cover with clips and attach to hook tabs, then pull tensioning wire tight and secure.

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Seat upholstery

Page 6 of 23 74-6

4 - Clamping strip 5 - Felt trim Attached to lower frame with hook tabs. Clamped to seat pan. 6 - Felt trim mounting point 7 - Hook tab 8 - Clip Connected in tensioning wire -3under seat pan. 9 - Seat frame 10 - Padding Removing: - Separate seat and backrest Page 72-2 - Remove cover and padding Page 743

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Seat upholstery

Page 7 of 23 74-7

Cover and padding, removing - Loosen felt trim -2- in area of backrest mounting. - Disconnect left and right tensioning wire -1-. Note: When attaching wire -1-, re-tension it slightly.

- Remove clips -1- and open left and right hooks -2-.

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Seat upholstery

Page 8 of 23 74-8

- Remove retention strip -1- from seat pan.

- Roll up cover until cover wires -1- are visible. - Unhook cover wires -1- with awl VAG1636 and remove cover. - Remove padding from seat frame, if necessary disconnect connector for seat heater. Note: To make it easier to install, warm cover to about 30 C (86 F).

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Seat upholstery

Page 9 of 23 74-9

Backrest cover and padding, removing and installing 1 - Cover Removing: - Separate seat and backrest Page 72-2 - Completely unhook underside clip section - 14 -. - Sport seat: Unhook tensioning wire - 3 at securing points 13 -. - Slide cover up. - Sport seat: Cut cover clamps - 4 -. - Unhook upholstery wire - 2 -. - Remove guides - 8 or - 9 - and take cover off.

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Seat upholstery

Page 10 of 23 74-10

2 - Upholstery wire (standard and sport seats) Connected in padding. Disconnect and connect with awl VAG1636. 3 - Upholstery wire (sport seat only) Hook into upholstery wire at top and at bottom - 13 -. Fasten upholstery wire going across with upholstery clips to upper rod - 7 -. 4 - Upholstery clips (3 clips, for sport seat only) Install with upholstery clip pliers VAG1634. 5 - Padding 6 - Backrest frame

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Page 11 of 23 74-11

7 - Cross rod For attaching upholstery wire to backrest frame, sport seat only. 8 - Guide (for CL version) To remove, push cover up, squeeze ends of guide together and pull out. 9 - Guide (GL and GT versions) To remove, press locking lug (arrow) with screwdriver toward rear and pull out guide. 10 - Trim (Taxi only) 11 - Screw

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Page 12 of 23 74-12

12 - Protective strip Glue on with adhesive D 001 200. 13 - Securing point for upholstery wire 14 - Clip section Located on front and back side of cover.

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Seat upholstery

Page 13 of 23 74-13

Rear seat cover and padding, removing and installing 1 - Cover Removing: - Pry out welt from seat pan flange - 8 -. - Unhook upholstery wires. 2 - Padding 3 - Upholstery wire Hooked into padding, remove and install with awl VAG1636. 4 - Strap Hooked into seat pan flange.

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Seat upholstery

Page 14 of 23 74-14

5 - Locking hook To remove, loosen seat cover on the side. 6 - Self-tapping screw 7 - Support with rubber pad 8 - Seat pan

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Seat upholstery

Page 15 of 23 74-15

Backrest (split) covers and padding, removing and installing 1 - Cover (dual seat) Lock, removing and installing Page 7419 Center armrest, removing Page 7422 Upholstery clips, removing and installing Page 74-23 Cover is fastened with sewn-in clamping strip to flange of rear panel. 2 - Upholstery wire Hooked into padding, remove and reinstall with awl VAG1636. 3 - Padding

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Page 16 of 23 74-16

4 - Rear panel (dual seat) Trim is self-adhesive. Remove protective foil before assembly. If necessary re-glue with adhesive D 001 200. 5 - Head restraint To remove, press button on guide and pull out restraint. 6 - Guide To remove, loosen cover at rear panel, squeeze end of guide together and pull out guide. Installation position for Sedan: Guide button must point toward right. Installation position for Wagon: Guide button must point toward left.

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Seat upholstery

Page 17 of 23 74-17

7 - Support bracket Wagon only. 8 - Spacer block Wagon only. Clipped into rear panel. 9 - Rear panel (single seat) Trim is self-adhesive. Remove protective foil before assembly. If necessary re-glue with adhesive D 001 200. 10 - Socket-head bolt 11 - Adapter 12 - Cover (single seat) Lock, removing and installing Page 7419 13 - Socket-head bolt 14 - Adapter

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Page 18 of 23 74-18

15 - Mounting pin For center armrest. 16 - Bracket for armrest 17 - Trim piece 18 - Box section Note locking lug when removing and installing.

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Page 19 of 23 74-19

Backrest lock, removing and installing 1 - Escutcheon 2 - Screw 3 - Lock cylinder 4 - Locking pin With spring. 5 - Guide 6 - Screw 7 - Lock 8 - Release lever 9 - Clip 10 - Cover

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Page 20 of 23 74-20

11 - Screw 12 - Counter-sunk screw 13 - Lock housing To remove, remove cover and padding Page 74-15

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Page 21 of 23 74-21

Heater element for seat, installing Note: When installing material -1- of heater element, it must be connected with backrest cover and backrest frame -2- in the groove (depression) utilizing two sided tape. The heater element must be installed over the head rest adjuster guide holes -3- and secured with head rest guide.

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Page 22 of 23 74-22

Center armrest, removing - Fold down left backrest. - Press release button -1- and fold down center armrest. - Remove mounting pin -2-. - Press release button -1- and remove armrest.

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Page 23 of 23 74-23

Upholstery clips, removing and installing Removing - Cut through upholstery clips. Installing - Install upholstery clips -1- with upholstery clip pliers VAG1634 to upholstery wire -2-.

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12/7/2004