VW Books Catalogue

transcript

Rear lid

of 1Rear lid

22/11/2009vw-wi://rl/N.en-GB.K03589810.wi::35009344.xml?xsl=3

ToolsSpecial tools and workshop equipment required

Torque wrench -V.A.G 1783-

Socket -T10010-

of 2Tools

Assembly overview - rear lid1 - Rear lid

Removing and installing → Chapter

Adjusting → Chapter

2 - Lid lock Removing

and installing → Chapter

3 - Handle trim Removing

4 - Damper Adjusting

→ Chapter

5 - Gas-filled strut Removing

→ Chapter Releasing

gas → Chapter

6 - Striker pin Adjusting

rigid striker pin → Chapter.

Adjust striker pin using power latching system → Chapter

7 - Guide pin Adjusting → Chapter

8 - Hinge Removing and installing → Chapter

of 1Assembly overview - rear lid

Removing and installing rear lid

of 1Removing and installing rear lid

Removing

– Open rear lid -1-.

– Remove rear lid trim → General body repairs, interior; Rep. Gr.70.

– Disconnect connectors from existing electrical components and washer system hose (if fitted) → Electrical system; Rep. Gr.92

– Disconnect connector for high-level brake light → Electrical system; Rep. Gr.94

– Disconnect connector from rear lid lock. Remove rear lid lock → Chapter

– Guide hoses and wiring out through opening.

– Loosen bolts -2- at hinges -3- on left and right (do not remove).

– Further dismantling is possible only with the help of a second mechanic.

– Detach gas-filled struts -4- on left and right of rear lid -1- → Chapter.

– Only now unscrew bolts -2- and remove rear lid -1- from body.

of 1Removing

Installing

Rear lid -1- installation is performed in the reverse order of removal.

– Tighten bolts -2- to 20 Nm.

Carry out corrosion protection measures on lid hinge and securing bolts after assembly work.

of 1Installing

Removing gas-filled strut– Open rear lid

and support it.

– Position a small screwdriver beneath spring clip -2-.

– Raise spring clip -2- until spring clip can be moved over ball socket in -direction of arrow-.

– Pull gas-filled struts -1- from ball-head pins -3- and -4-.

After removing gas-filled strut -1-, slide spring clip -2- back immediately.

WARNINGProceed with care if gas-filled strut is reused. Spring clip must not be levered completely out of ball socket, as it will otherwise be damaged. Gas-filled strut springs out of mounting and causes damage or injury to operator.

– Specified torque for ball-head pins -3- and -4-20 Nm.

– Releasing gas from gas-filled strut -1-→ Chapter.

of 1Removing gas-filled strut

Removing and installing handle trim

of 1Removing and installing handle trim

Removing– Remove rear lid trim → General body

repairs, interior; Rep. Gr.70.

– Disconnect connector -2- for number plate lights from handle trim -1-.

– Remove the hexagon nuts -3- (Qty. 4) and remove handle trim -1- from the outside.

of 1Removing

InstallingHandle trim -1- installation is carried out in reverse order of removal.

– Tighten hexagon nuts -3- to 4.5 Nm.

of 1Installing

Removing and installing rear lid hinges

Removal and installation is described for the right hinge only. Apply the same instructions for the left-hand side as appropriate.

of 1Removing and installing rear lid hinges

Removing

– Remove rear lid -1- → Chapter

– Remove rear roof trim → General body repairs, interior; Rep. Gr.70

– Remove the hexagon nuts -2- (Qty. 2) and remove base plate -1- from studs.

Hexagon nuts -2- can only be loosened with a “long-shaft socket”, as rear lid hinge guide bolts are too long.

– Remove rear lid hinge from outside.

of 1Removing

Installing

Before installing rear lid hinge -2- check seal -3- for damage and renew if necessary. Hexagon nuts -5- can only be loosened with a “long-shaft socket”, as rear lid hinge guide bolts are too

– Position rear lid hinge -2- from outside.

– Slide base plate -4- onto studs on inner roof member and fit hexagon nuts -5-.

– Tighten hexagon nuts -5- to specified torque of 20 Nm.

– Adjust rear lid -1- → Chapter.

Carry out corrosion protection measures on lid hinge and securing bolts after assembly and adjustment work.

of 1Installing

Adjusting rear lidThe rear lid can be adjusted only via the striker pin on lock cross member. The rear lid lock is bolted to the rear lid, it does not have elongated holes and therefore cannot be adjusted.

The buffers and guide wedges cannot be used to adjust the rear lid. They have the function of stabilising and damping the rear lid.

In conclusion, the rear lid adjustment is described in several steps. This includes the basic adjustment of the rear lid, the striker pins, guide pins and the dampers.

of 1Adjusting rear lid

Adjusting rear lidThe rear lid can be adjusted only via the striker pin on lock cross member. The rear lid lock is bolted to the rear lid, it does not have elongated holes and therefore cannot be adjusted.

The buffers and guide wedges cannot be used to adjust the rear lid. They have the function of stabilising and damping the rear lid.

In conclusion, the rear lid adjustment is described in several steps. This includes the basic adjustment of the rear lid, the striker pins, guide pins and the dampers.

of 1Adjusting rear lid

Basic adjustment of rear lid

Vehicle must be standing on its wheels when adjustments are performed.

The rear lid is adjusted correctly if the shut lines/gaps are uniform all around, the lid is not too deep or too high and all contours align when lid is closed → Rep. Gr.00.

– Remove rear roof trim → General body repairs, interior; Rep. Gr.70.

– Remove gas-filled strut for rear lid → Chapter.

– Remove bumper cover end piece → Chapter.

– Loosen bolts -3- and -4- until guide pins -1-move freely on left and right sides. The striker wedges -2- must move in the guide pins without resistance.

– Loosen hexagon nuts -1- in rear roof member cut-out -2- (do not remove).

Hexagon nuts -1- can only be loosened with a “long-shaft socket”, as rear lid hinge guide bolts are too long.

– Align rear lid uniformly according to outer contours -arrows- on left and right, the assistance of a second mechanic is required.

of 2Basic adjustment of rear lid

– Tighten hexagon nuts -1- to 20 Nm.

– Adjusting guide pins → Chapter.

of 2Basic adjustment of rear lid

Adjusting striker pin

– The rear floor edge cover must be removed to adjust the rear striker pin → General body repairs, interior; Rep. Gr.70.

– The guide pins must be loose → Chapter.

– Loosen bolts -2- (do not remove) and striker pin -1- can be moved within over-size holes.

– Move striker pin -1- to rearmost position -arrow- and tighten bolts -2-

– Close rear lid and check adjustment.

– Following adjustment, retighten bolts -2- to specified torque of 20 Nm.

– Now the guide pins can be adjusted → Chapter.

of 1Adjusting striker pin

Adjusting striker pin for power latching system

The battery must be fully charged and connected on vehicles with power latching system.

– The rear floor edge cover must be removed to adjust the rear striker pin on vehicles with power latching system → General body repairs, interior; Rep. Gr.70.

– The guide pins must be loose → Chapter.

– Loosen bolts -2- (do not remove) and striker pin (on vehicles with power latching system) -1- can be moved within over-size holes.

– Move striker pin -1- (on vehicles with power latching system) to rearmost position -arrow- and tighten bolts -2- (not fully).

– Close rear lid and check adjustment.

– Following adjustment, retighten bolts -2- to specified torque of 20 Nm.

– Now the guide pins can be adjusted → Chapter.

of 1Adjusting striker pin for power latching system

Adjusting guide wedge and guide pin

of 1Adjusting guide wedge and guide pin

Assembly overview1 - Bolt

Qty. 2 Specified

torque 8 Nm

2 - Guide pin Left and right

3 - Bolt Qty. 2 Specified

torque 8 Nm

4 - Guide wedge Left and right

of 1Assembly overview

Adjusting guide pins– Remove bumper cover end pieces → Chapter.

– The striker pin must be correctly positioned before adjusting guide pins.

– Adjust striker pin → Chapter

– Loosen bolts -3- and -4- (do not remove) until guide pins -1- move freely on left and right sides. The striker wedges -2- must move in the guide pins without resistance.

– Close rear lid.

– Press the guide wedge -2- against the guide pin -1- with slight force and tighten the bolts.

– Open rear lid and tighten bolt -3- to 15 Nm and bolt -4- to 8 Nm.

of 1Adjusting guide pins

Adjusting stop buffers

– Loosen clamping bolt -2- until it is visible in rubber buffer.

– Pull detent slide -1- out from housing.

– Adjust detent slide to dimension -a = 12.5 mm-.

– Close rear lid with light pressure at centre of lid. Keep pulling on handle whilst doing this.

– Open rear lid again.

– Screw in clamping screw -1- to dimension -

of 2Adjusting stop buffers

a = 25 mm-.

Check setting.

of 2Adjusting stop buffers

Assembly overview - rear lid latch and release components

of 1Assembly overview - rear lid latch and release components

Assembly overview - lock carrier

1 - Carrier for locking mechanism With central locking

and interior release mechanism

2 - Locking rod for door interior opening mechanism

3 - Bearing plate

4 - Exterior handle Removing and

installing → Chapter

5 - Lock operating lever

6 - Lock Removing and

7 - Connector

8 - Child-proof control For vehicles with

moulded trim Removing and

9 - Trim For vehicles with

moulded trim → General body repairs, interior; Rep. Gr.70.

10 - Bolt Qty. 3 Specified torque 4.5 Nm

11 - Anti-theft protection

12 - Lock cylinder Removing and installing → Chapter Lock cylinder can only be removed outwards in -direction of arrow- from latch carrier.

13 - Operating rod for door interior opening mechanism

14 - Rear lid Removing and installing → Chapter Adjusting → Chapter

of 1Assembly overview - lock carrier

Assembly overview - lock cylinder housingFor vehicles with no inner operating mechanism

1 - Handle

2 - Bolt Qty. 2 20 Nm

3 - Bonnet lock Removing

→ Chapter Installing

→ Chapter

torque 4.5 Nm

5 - Pull rod

6 - Lock cylinder housing Removing

7 - Retaining clip

8 - Pull rod

9 - Central locking control motor Removing:– Separate

connector on control motor

– Unscrew control motor using socket driver -T10010- and unhook out of rear lid.

Installing:– Install in reverse order of removal.

of 1Assembly overview - lock cylinder housing

Removing and installing rear lid lock

of 1Removing and installing rear lid lock

Removing

– Remove rear lid trim → General body repairs, interior; Rep. Gr.70

– Unclip operating rod -1- on latch carrier.

– Unscrew bolts -3- and pull rear lid lock slightly out of rear lid.

– Disconnect connector -4- from lid lock -2-.

– Remove rear lid lock -2- with operating rod -1- from rear lid.

of 1Removing

Installing

– Rear lid lock -2- installation is carried out in reverse order of removal.

– Tighten bolts -3- to 20 Nm.

Operating rod and lid lock must be installed without stress. Before installing rear lid trim and closing rear lid, check function of the lid locking and release components.

of 1Installing

Removing and installing childproof lock operating device

of 1Removing and installing childproof lock operating device

Removing– Remove cover -2-, remove rear lid trim

→ General body repairs, interior; Rep. Gr.70

– Clip the child-safety control lock -3- out of the inner part of the lid -4-.

– Unclip the child-safety control lock -3-out of the inner part of the lid -4--arrow a-.

– Next swing out the child-safety control lock -3- out of the inner part of the rear lid -4-using the extension -1--arrow b-.

of 1Removing

Installing– Swing the child-safety control lock -4- into

the inner part of the lid -5--arrow a-.

– Guide the extension -2- of the child-safety control lock -4- into the carrier part -1--arrow b-.

– Engage the child-safety control lock -4- in the inner part of the lid -5-.

– Remove cover -3- and fit rear lid trim → General body repairs, interior; Rep. Gr.70.

of 1Installing

Removing and installing carrier for rear lid locking

The removal and installation procedures may have to be revised slightly depending on model.

of 1Removing and installing carrier for rear lid locking

Removing– Remove rear lid trim → General body repairs, interior; Rep.

– Remove rear lid lock → Chapter

– Release rods on inner operating mechanism on left-hand side → Chapter

– Disconnect connections -1-.

– Unclip operating rods from latch carrier.

– Unscrew bolts -2- and remove anti-theft protection -3- for lock cylinder.

of 4Removing

– Use screwdriver to lever lock cylinder retaining clip to side, in -direction of arrow-, and remove clip.

– Press left and right locking tabs -arrows- on latch carrier to side and pull latch carrier out a few millimetres from inner part of lid.

– The lock cylinder must remain engaged in the latch carrier.

Before exterior handle can be removed, set lock cylinder to locking position.

– Remove exterior handle -1- without lock cylinder with handle in pulled position -2-.

of 4Removing

– Press centre locking tab on latch carrier -arrow a - back from inner part of lid.

of 4Removing

– Remove latch carrier -1-, together with striker plate, as a single unit from rear lid in -direction of arrow-.

of 4Removing

Installing– Install retaining clip for lock cylinder -

arrow- on exterior handle.

– Further installation is performed in the reverse order of removal.

Ensure that retaining clip -arrow- is correctly engaged in exterior handle.

Ensure that lock cylinder is also set to locking position on installation and that the locking unit is therefore locked. If this is not carried out, the exterior handle cannot be installed properly, and malfunctions occur.

Before installing rear lid trim and closing rear lid, check function of the lid locking and release components.

of 1Installing

Removing and installing lock cylinder

of 1Removing and installing lock cylinder

Removing– Remove rear lid trim → General body repairs, interior; Rep.

– Remove exterior handle → Chapter

– Press lock cylinder -2- in -direction of arrow- out of latch carrier -1-.

Ensure that lock cylinder is set to “locking unit open” position on removal! If this is not carried out, lock cylinder cannot be disengaged from locking unit.

of 1Removing

Installing– Press lock cylinder -2- in -direction of

arrow- into latch carrier -1- from outside.

– Lock cylinder -2- must audibly engage in latch carrier -1-.

– Install exterior handle → Chapter.

Further installation is performed in the reverse order of removal.

Ensure that lock cylinder is also set to “locking unit open” position on installation! If this is not carried out, lock cylinder cannot be engaged in locking unit.

of 1Installing

Removing and installing lock cylinder housingFor vehicles with no inner operating mechanism

1 - Handle

2 - Guide sleeves

3 - Grip moulding

4 - Seal

5 - Retaining clip

6 - Shaft

7 - Locking ring

8 - Spring

9 - Seal

10 - Lock cylinder housing Removing:– Remove rear

lid trim → General body repairs, interior; Rep. Gr.70.

– Unclip push rod for lid lock (if necessary securing rod for central locking) → Item

– Lever out circlip -5-and remove lock cylinder housing from grip moulding -3-

Installing:– Engage circlip -5- again.– Bring lock cylinder housing into contact with handle trim and engage in handle. Housing can be

heard to lock in place.– Further installation is performed in the reverse order of removal.

11 - Linkage clip For rear lid lock → Item

12 - Linkage clip For control motor → Item

of 1Removing and installing lock cylinder housing

Interior opening mechanism

of 1Interior opening mechanism

Assembly overview1 - Trim

2 - Interior opening mechanism Removing

→ Chapter Installing

→ Chapter

3 - Securing clip for operating rod

4 - Operating rod for door interior opening mechanism

5 - Locking rod for door interior opening mechanism

6 - Lock mechanism

Removing

– Remove rear lid trim → General body repairs, interior; Rep. Gr.70

– Release retaining clip -5- and unclip interior opening mechanism operating rod -4- from locking unit -3-.

– Unclip locking mechanism linkage -2- from locking unit -3-.

– Lever locking tabs -arrow b- upwards and pull interior opening mechanism -1- from rear lid retainer in -direction of arrow a-.

– Remove interior opening mechanism -1- with locking mechanism linkage from inner part of rear lid.

of 1Removing

InstallingInstallation is the reverse of removal.

of 1Installing

Removing and installing rear lid seal

During production, a sealant is applied to the rear lid seals, the seal is then placed on the door flange and rolled on.

When seals are removed, the sealant will spread to the inside of the seal and the flanks will be bent out slightly. If the seal is then refitted, a tight seal is not guaranteed.

Therefore each seal which is removed completely should be replaced by a so-called “tap-on” seal.

If a seal has been partially removed, squeeze sides of seal together before installing.

of 1Removing and installing rear lid seal

Removing– Remove interior trim panels (as necessary

and if fitted) → General body repairs, interior; Rep. Gr.70

– Pull rear lid seal -1- off body flange.

of 1Removing

Installing– The vulcanised point -arrow- on the rear lid

seal -arrow- must be aligned to the middle of the rear left light cluster.

– Install interior trim panels (as necessary and if fitted) → General body repairs, interior; Rep. Gr.70

of 1Installing

Rear lid trims

of 1Rear lid trims

22/11/2009vw-wi://rl/N.en-GB.k00589832.wi::31322209.xml?xsl=3

Release lever -T10039-

Pop-rivet nut pliers -V.A.G 1765B-

of 1Tools

Removing and installing window frame trim for rear lid

of 1Removing and installing window frame trim for rear lid

Removing

– Switch off ignition.

– Pull window frame trim -2- off window frame, starting at sides.

of 1Removing

Installing

Before installing, check fasteners -1- for damage and renew if necessary.

– Installation is carried out in reverse order of removal.

of 1Installing

Removing and installing lower rear lid trim

of 1Removing and installing lower rear lid trim

RemovingAll vehicles

– Remove rear lid window frame trim → Chapter.

Only vehicles with additional inner lock in rear lid

On this equipment level the “locking cylinder cover of the child lock” and the “inner lock trim” must also be removed.

– Carefully push “inner lock trim” upwards and pull off trim from panel.

– Insert 2 twist drills (� 1 mm) to depth of 15 mm in openings of “locking cylinder cover for childproof lock”, push drill bits together and pull out cover from mountings.

CautionDamage to rear lid trim.

Trim must be renewed if care is not exercised.

of 2Removing

Carefully release trim around lid lock first.

– When trim is released, continue at corners.

– Do not simply pull trim down, but grasp behind trim with fingers and press against the rear lid with the thumb.

– Once trim is release to the corners, release remainder of trim.

– Remove bolts -3- (Qty 2).

– Hold trim with one hand and remove the pull loop -4- with other hand.

– The trim is now completely free and can be removed.

– Remove the clips that remain in the rear lid using release lever -T10039-.

of 2Removing

Installing

Before installing, check fasteners -1- for damage and renew if necessary. When installing pull loop -4- ensure spacers -2- are seated correctly.

– Installation of the lower trim for the door basically is the reverse of removal.

Tighten bolts -3- to specified torque of 4 Nm.

of 1Installing

Assembly overview - hardboard trim for lower area of rear lid1 - Rear lid

2 - Pop-rivet nut Qty. 2 Insert with

pop-rivet nut pliers -V.A.G 1765B-

3 - Hardboard trim for lower area of rear lid Removing

4 - Clip Qty. 17

torque: 3.5 Nm

6 - Pull loop

7 - Cover for wiper motor

8 - Grommet Qty. 2

of 1Assembly overview - hardboard trim for lower area of rear lid

Removing and installing lower hardboard trim for rear lid

of 1Removing and installing lower hardboard trim for rear lid

Removing

– Unclip wiper motor cover -7- from rear lid.

– Remove bolts -5- and remove pull loop -6-.

– Remove pin using 3 mm hexagon key and pull out spreader rivets -4-

– Remove lower hardboard trim -3- from rear lid -1-.

of 1Removing

Installing

Before installing, check securing clips for damage and renew if necessary.

of 1Installing

Rear window wiper system (vehicles with rear lid)Fault detection and fault display

The convenience system central control unit -J393- is equipped with a self-diagnosis function, which makes fault finding easier.

Use the “guided fault finding” mode on the vehicle diagnosis, testing and information system -VAS 5051- to perform fault finding.

CautionTo disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to → Chapter.

of 1Rear window wiper system (vehicles with rear lid)

Rear window wiper motor -V12-

of 1Rear window wiper motorV12

Assembly overview

CautionEnsure rubber seals -1- for wiper shaft are seated correctly in door panel.

Apply lubricant: polyethyleneglycol to wiper shaft -6-.

1 - Rubber seal (Use seal with marking pointing upwards with a deviation of -a-= ±10°)

2 - Rear lid3 - Securing nuts4 - Hose connection for windscreen

washer system5 - Rear window wiper motor -V12-6 - Wiper shaft (use polyethyleneglycol as

lubricant during installation)

RemovingSpecial tools and workshop equipment required

Torque wrench (5 - 50 Nm) -V.A.G 1331-

– Allow rear window wiper to move to park position.

– Disconnect battery → Chapter.

– Unclip cover cap -1- of rear window wiper outwards.

– Remove hexagon nuts -1-.

– Release wiper arm from wiper motor shaft by rocking arm sideways.

– Remove lower rear lid trim → General body repairs, interior; Rep. Gr.70

of 2Removing

– Pull connector -1- off wiper motor.

– Pull off hose connection piece -2- for window washer system.

– Remove hexagon nuts -3-.

– Remove wiper motor -4-.

of 2Removing

InstallingCarry out installation in the reverse sequence, noting the following:

CautionEnsure rubber seal for wiper shaft is seated correctly in door panel

– Insert rubber seal → Anchor.

CautionApply lubricant to the wiper shaft before inserting rear window wiper motor, right wing door -V93-.

– Insert rear window wiper motor, right wing door -V93-→ Anchor.

– Tighten hexagon nuts -3- for wiper motor to 8 Nm.

– Loosely screw wiper arm securing bolt on wiper arm shaft.

– Adjust rear window wiper park position → Chapter.

– Install lower rear lid trim → General body repairs, interior; Rep. Gr.70.

– Reconnect battery → Chapter.

of 1Installing

Removing and installing windscreen wiper bladesRemoving

– Allow windscreen wipers to move to park position.

– Switch off ignition and all electrical consumers and remove ignition key.

– Flap windscreen wiper arm -1-away from windscreen, thereby gripping the wiper blade -2- only at the wiper arm fixation.

Avoid bending the windscreen wiper arm and blade.

Avoid windscreen wiper arm springing back unintentionally and damaging the glass.

– Pull windscreen wiper blade -2-90� to windscreen wiper arm -1-and back again.

– Pull plastic cap off windscreen wiper arm -arrow 1-.

– Remove windscreen wiper blade -2-from axis of windscreen wiper arm -1- in the direction of -arrow 2-.

Installing

– Install the windscreen wiper blade -2- in the reverse sequence.

– Push -arrow 1-windscreen

of 2Removing and installing windscreen wiper blades

wiper blade -2-onto axis of windscreen wiper arm -1-.

– Fasten the windscreen wiper blade by tightening the plastic cap -arrow 2- until the cap notches.

– Push windscreen wiper arm back onto window.

– Check windscreen wiper blade park position and if necessary, adjust → Chapter.

of 2Removing and installing windscreen wiper blades

Adjusting rear window wiper park positionSpecial tools and workshop equipment required

Torque wrench (5 - 50 Nm) -V.A.G 1331-

– Allow wiper to move to park position.

Distance -a- between wiper blade and lower edge of window should be 25 mm.

– If necessary, adjust rear window wiper blade park position by moving wiper arm on shaft.

– Tighten securing nut of wiper arm to specified torque of 12 Nm.

of 1Adjusting rear window wiper park position

Rear window washer system (vehicles with rear lid)Fault detection and fault display

The convenience system central control unit -J393- is equipped with a self-diagnosis function, which makes fault finding easier.

Use the “guided fault finding” mode on the vehicle diagnosis, testing and information system -VAS 5051- to perform fault finding.

CautionTo disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to → Chapter.

of 1Rear window washer system (vehicles with rear lid)

Assembly overview - rear window washer system (vehicles with rear lid)1 - Spray jet for

rear window washer system– Integrated in

drive shaft of rear wiper motor

Adjusting → Chapter

2 - Connection piece Connection

to rear window spray jet

Overview of hose couplings for washer fluid lines → Chapter

3 - Connection piece Separating

point between roof wiring harness and rear lid wiring harness

Overview of hose couplings for washer fluid lines → Chapter

4 - Hose Hose repair → Chapter

5 - Angled piece Connection to windscreen and rear window washer pump– Colour of connection to windscreen spray jets - black– Colour of connection to rear window spray jet - white Overview of hose couplings for washer fluid lines → Chapter

6 - Windscreen and rear window washer pump -V59- Removing and installing → Chapter

7 - Reservoir for windscreen and headlight washer system

of 2Assembly overview - rear window washer system (vehicles with rear lid)

Size of reservoir depends on whether vehicle has headlight washer system Removing and installing → Chapter

8 - Filler pipe for reservoir for windscreen washer and headlight washer system Removing and installing filler pipe → Chapter

of 2Assembly overview - rear window washer system (vehicles with rear lid)

Renewing washer spray jet

of 1Renewing washer spray jet

Removing– Allow rear window wiper to move to park position.

– Unclip cover cap -1- of rear window wiper outwards.

– Using suitable long-nose pliers, carefully pull out washer spray jet in -direction of arrow-.

of 1Removing

InstallingInstall in reverse order of removal.

of 1Installing

Adjusting washer spray jetAdjusting washer spray jet → Booklet19.1

of 1Adjusting washer spray jet

Windscreen wash/wipe system and headlight washer system: Check function and settings Check anti-freeze concentration of Windscreen Clear with

anti-freeze -G 052 164-, replenish with fluid if necessary → Chapter.

Windscreen wash/wipe system: Check spray jet settings and adjust if necessary → Chapter.

Headlight washer system: Check spray jet settings, adjust if necessary → Chapter

Checking Windscreen Clear with anti-freeze of windscreen wash/wipe system, replenishing with fluid if necessaryChecking anti-freeze concentration

Special tools and workshop equipment required

Refractometer -T10007-

Read precise value for the following tests at bright/dark boundary. Using a pipette, place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognised on the “WATERLINE”.

– Check concentration of anti-freeze additive using refractometer -T10007- (refer to operating instructions).

The scale -1- of the refractometer is calibrated for Genuine Volkswagen Windscreen Clear with anti-freeze -G 052 164-.

The scale -2- is designed for commercially available windscreen cleanser as well as a mixture of commercially available windscreen cleanser and genuine Volkswagen Windscreen Clear with anti-freeze -G 052 164-.

Mixture ratio

Frost protection to Windscreen Clear with anti-freeze

of 5Windscreen wash/wipe system and headlight washer system: Check function and setti...

22/11/2009vw-wi://igg/N.en-GB.k00589828.wi::34012073.xml?xsl=3

G 052 164

-17/-18 °C 1 part 3 parts

-22/-23 °C 1 part 2 parts

-37/-38 °C 1 part 1 part

Replenishing with fluid

The fluid reservoir of the window washer system must be filled completely.

Starting immediately, use only Genuine Volkswagen Windscreen Clear with anti-freeze -G 052 164- all-year-round when replenishing windscreen wash/wipe system.

All vehicles having fan-type spray jets, the reservoir must be filled with Windscreen Clear with anti-freeze -G 052 164-, as this fluid has a low viscosity at temperatures below freezing. Otherwise the complicated spray jet system can become blocked by the crystallised washer fluid, which affects the spray pattern of the spray jet. Windscreen Clear with anti-freeze -G 052 164- ensures that the fan-type spray jets remain fully functional also at low temperatures.

Genuine Volkswagen Windscreen Clear with anti-freeze -G 052 164- protects the spray jets, fluid reservoir and connecting hoses from freezing.

Use Genuine Volkswagen Windscreen Clear with anti-freeze -G 052 164- in the warmer periods of the year also. The powerful cleanser removes wax and oil residue from the glass.

Frost protection must be guaranteed to approx. -25 °C (approx. -35 °C in countries with an arctic climate) in the windscreen wash/wipe system.

Windscreen wash/wipe system: Check spray jet settings and adjust if necessarySpecial tools and workshop equipment required

Setting device -T10127 -equipped with needle 3125/5 A

The spray jets may be cleaned in both directions, also opposite to direction of spray with compressed air or water.

Never use a needle or similar object, as otherwise water passages in spray jets will be damaged!

Windscreen spray jet settings:

The washer jets are preset. However, small height differences can be compensated for.

– If both spray fields are not at same height, adjust spray direction upwards or downwards as follows:

– Adjust the spray jet at adjuster -1- by hand.

Rear window spray jet setting / tailgate:

– Remove cap above drive shaft -2-.

– Adjust spray jet -1- using adjusting tool -T10127 - so that the water jet sprays onto the upper third of rear window.

Rear window spray jet setting / rear wing doors:

– Adjust spray jet using adjusting tool -T10127 - so that the water jets spray onto rear window at positions shown.

Mark the points at which water strikes the window with a water-soluble pin.

Dimension a = approx. 150 mm Dimension b = approx. 250 mm

Headlight washer system: Check spray jet settings, adjust if necessarySpecial tools and workshop equipment required

Adjusting tool -T10167-

The jet adjustment dimensions are for the left-hand headlight (right-hand headlight mirror image)

Checking jet setting

– Switch on dipped headlight.

– Operate windscreen washer system.

The headlights are washed if the windscreen wiper lever is hold in “Wipe position” for at least 1.5 seconds.

The spray jet should spray on the positions illustrated.

Adjusting jets

– Switch on dipped headlight.

– Operate windscreen washer system.

The headlights are washed if the windscreen wiper lever is hold in “Wipe position” for at least 1.5 seconds.

The spray jets -arrows- are extended.

– Perform the following procedure:

– Align the spray direction of respective jet using adjusting tool -T10167- at points illustrated.

Mark the points at which water strikes the headlight with a water-soluble pin.

“a” approx. 127 mm “b” approx. 236 mm “c” approx. 100 mm “d” approx. 88 mm

If stream of water is uneven or cannot be adjusted to specified dimensions, renew washer jet (repair measure).

High level brake light bulb -M25-

of 1High level brake light bulbM25

Rear lid

of 1Rear lid

Removing and installing high-level brake light -M25-Removing

– Switch off ignition and all electrical consumers and remove ignition key.

– Remove upper rear lid trim → General body repairs, interior; Rep. Gr.70.

– Remove securing bolts -arrows-.

– Lift bulb for high-level brake light -M25-and loosen 2-pin connector -arrow-.

Installing

Installation is carried out in the reverse sequence. Observe specified torque of 1.5 Nm.

of 1Removing and installing high-level brake lightM25

Renewing bulbs/ light emitting diodes (LED)

The high-level brake light -M25- must be replaced as a complete unit in the event of repairs.

of 1Renewing bulbs/ light emitting diodes (LED)

Roof trims

of 1Roof trims

Release lever -T10039-

of 1Tools

Removing and installing roof frame trim

of 1Removing and installing roof frame trim

Removing

– Open rear lid.

– Remove upper D-pillar trim → Chapter.

– Pull roof frame trim -1- downwards out of mountings in roof cross member -4- and out of beading of rear lid seal -2-.

of 1Removing

Installing

Before installing, check fasteners -3- for damage and renew if necessary. After installing, check that roof frame trim -1- is completely in beading of rear lid seal -2-.

of 1Installing

Assembly overview - roof frame trim

Depending on model slight differences are possible when referring to assembly overview.

1 - Roof frame trim Without right

and left sliding door.

2 - Roof frame trim With right

and left sliding door.

3 - Channel

4 - Securing clip At front and

rear only.

5 - Clip For roof

frame trim without sliding door.

Qty. 6

6 - Clip For roof

frame trim with sliding door.

Qty. 5

of 1Assembly overview - roof frame trim

Assembly overview - moulded headlining (Multivan)1 - Front seat area

moulded headlining

Removing → Chapter

2 - Bolts

Qty. 2, specified torque 2 Nm

3 - Passenger compartment moulded headlining

Removing → Chapter

4 - Securing clip

Qty. 8

5 - Clip holder

of 1Assembly overview - moulded headlining (Multivan)

Removing and installing moulded headlining for passenger compartment

Removal and installation is described for the Multivan. Follow same instructions for the Transporter as appropriate.

of 1Removing and installing moulded headlining for passenger compartment

Removing– Remove middle interior lights → Electrical system; Rep. Gr.96.

– Remove rear interior lights → Electrical system; Rep. Gr.96.

– Remove grab handles (B-pillar) → Chapter.

– Remove upper B-pillar trim (belt end anchors need not be removed) → Chapter.

– Remove retainers for net partition → Chapter.

– Remove upper C-pillar trim → Chapter.

– Remove upper D-pillar trim → Chapter.

– Remove rear roof frame trim → Chapter.

– Remove middle and rear roof grab handles → Chapter.

– Pull air duct hose -2- off air duct -1- on moulded headlining -3--arrow-.

– Lower rear section of moulded headlining -3- slightly and pull it to rear out of the clips.

– Pull moulded headlining -3- to rear out of vehicle.

of 1Removing

Installing– Remove the 8

clips -1- from the roof bows and insert then into the clip holders -2- (on back of moulded headlining).

– Position passenger compartment moulded headlining in installation position and clip into the roof.

– Further installation is performed in the reverse order of removal.

of 1Installing

Removing and installing moulded headlining in area of front seats

Removal and installation is described for the Multivan. Follow same instructions for the Transporter as appropriate.

of 1Removing and installing moulded headlining in area of front seats

RemovingOnly vehicles with a sunroof

– Remove passenger compartment moulded headlining → Chapter.

– Remove operating unit in roof console → Electrical system; Rep. Gr.96.

– Remove roof console → Chapter.

– Remove sun visors → Chapter.

– Remove vanity mirror light → Electrical system; Rep. Gr.96.

of 2Removing

– Remove grab handles (A-pillar) → Chapter.

– Remove A-pillar trims → Chapter.

– Push wedge -T10039/1- between frame -1- and moulded headlining -2-.

– Using release lever -T10039-, move along edges of moulded headliner and unclip headliner from frame -arrow-.

All vehicles

– Remove the 2 bolts -1-, specified torque 2 Nm.

– Remove front roof grab handles → Chapter.

– Pull front seat area moulded headlining to side out of vehicle.

of 2Removing

Installing– Installation is carried out in reverse order of removal.

of 1Installing

VW Books Catalogue

Documents