Volkswagen Golf 2004 Workshop Manual
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Volkswagen Golf 2004 Workshop Manual

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Service
Workshop Manual
Golf 2004 ➤
General body repairs, exterior
Edition 04.2008
Service Department. Technical Information

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Summary of Contents for Volkswagen Golf 2004

  • Page 1 Service Workshop Manual Golf 2004 ➤ General body repairs, exterior Edition 04.2008 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg K0058991620...

  • Page 3: Table Of Contents

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Contents 50 - Body - front ............
  • Page 4 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 57 - Front doors, door components, central locking ......45 Front door .
  • Page 5 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 60 - Sunroof ............118 Sliding/tilting sunroof with glass panel (Meritor) .
  • Page 6 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear bumper attachments ..........162 Rear bumper substructure .
  • Page 7 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing door window ........206 Assembly overview - fixed door window with window guide .
  • Page 8 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Attachment notes for protective backing ........266 Renewing scuff protection film .

  • Page 9: Body - Front

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 50 – Body - front Lock carrier Tools 1.1.1 Required special tools, workshop equip‐ ment, test and measuring devices and auxiliary items ♦ Guide pins -T 10093- ♦ Torque wrench 5...50 Nm -V.A.G 1331- ♦...

  • Page 10: Assembly Overview - Lock Carrier, Service Position

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - lock carrier, service position 1 - Lock carrier with add-on parts ❑ Removing and installing ⇒ page 4 ❑ Service position ⇒ page 3 2 - Bolt ❑...

  • Page 11: Service Position

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Service position 1.3.1 Moving to service position – Remove front bumper ⇒ page 140 , GTI ⇒ page 147 , R32 ⇒ page 151 – Unhook Bowden cable at coupling ⇒...

  • Page 12: Removing And Installing Lock Carrier With Add-On Parts

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.3.2 Moving from service position Install in reverse order of removal. – Align lock carrier to longitudinal members and between wings ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap di‐...
  • Page 13 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Set lock carrier with add-on parts -1- to service position ⇒ page 3 – Disconnect all electrical connectors. – Drain coolant and disconnect coolant lines ⇒ Engine cooling system; Rep. Gr. 19 ; Parts of cooling system; Draining and filling coolant .
  • Page 14 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note Do not hang condenser and hydraulic oil cooler from lines. ♦ Do not kink condenser and hydraulic lines. ♦ 1.4.2 Installing Install in reverse order of removal. • During assembly, ensure that all connectors and hose con‐...

  • Page 15: Wing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Wing Tools Special tools and workshop equipment required ♦ Torque wrench 2...10 Nm -V.A.G 1783- ♦ Hot air blower -V.A.G 1416- 2. Wing...

  • Page 16: Assembly Overview - Front Wing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - front wing Note Only the left side is shown. The right side is similar. 1 - Wing ❑ Removing and installing ⇒ page 8 2 - Bolt ❑...
  • Page 17 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.3.1 Removing – Remove front bumper ⇒ page 140 – Remove wheel housing liners ⇒ page 218 – Remove guide ⇒ Item 10 (page 143) – Loosen hexagon nut -6- and remove bolts -2-.

  • Page 18: Removing And Installing Wing Strut

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.3.2 Installing Install in reverse order of removal. – Always insert “zinc intermediate piece AKL 381 035 50” be‐ tween wing and side member. – Specified torque for bolts -2- and hexagon nuts -5-: 6 Nm.
  • Page 19 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove bolts -2- and remove wing strut -1-. 2.4.2 Installing – Install wing strut -1-. – Specified torque for bolts -2-: 6 Nm – Wing and wing strut are adjusted together to bonnet and bumper ⇒...

  • Page 20: Noise Insulation

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Noise insulation Tools Special tools and workshop equipment required ♦ Torque wrench 2...10 Nm -V.A.G 1783- Rep. Gr.50 - Body - front...

  • Page 21: Assembly Overview - Noise Insulation

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - noise insulation Note The removal and installation procedures may have to be modified slightly depending on engine fitted. 1 - Noise insulation ❑ Arrow points forwards ❑ Removing: –...

  • Page 22: Underbody Cladding

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Underbody cladding Tools Special tools and workshop equipment required ♦ Torque wrench 2...10 Nm -V.A.G 1783- Rep. Gr.50 - Body - front...

  • Page 23: Assembly Overview - Underbody Cladding

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - underbody cladding Note Only the left side is shown. The right side is similar. 1 - Underbody cladding ❑ Arrow points forwards ❑ Removing: – Remove hexagon nuts 2 - Hexagon nut ❑...

  • Page 24: Plenum Chamber Bulkhead

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Plenum chamber bulkhead Tools Special tools and workshop equipment required ♦ Torque wrench 2...10 Nm -V.A.G 1783- Assembly overview - plenum chamber bulkhead 1 - Plenum chamber bulkhead 2 - Hexagon nut ❑...

  • Page 25: Bonnet, Rear Lid

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 55 – Bonnet, rear lid Bonnet Tools Special tools and workshop equipment required ♦ Torque wrench 5...50 Nm -V.A.G 1331- ♦ Removal lever -80-200- 1. Bonnet...

  • Page 26: Assembly Overview - Bonnet

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bonnet 1 - Bonnet ❑ Removing and installing ⇒ page 19 ❑ Adjusting ⇒ page 26 2 - Adjustment buffer ❑ Qty. 2 ❑ Adjusting ⇒ page 26 3 - Stop buffer ❑...

  • Page 27: Removing And Installing Bonnet

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing bonnet 1.3.1 Removing – Remove left and right washer jets -6- ⇒ Electrical system; Rep. Gr. 92 ; Window wiper/washer system; Windscreen washer system; Removing and installing windscreen washer system jets .

  • Page 28: Removing Gas Strut

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Specified torque for bonnet hexagon nut: 22 Nm. – Adjusting bonnet -1- ⇒ page 26 – Route line -2- in an arc -arrow-. If line is installed twisted it will be kinked.
  • Page 29 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.6.1 Removing – Remove bonnet ⇒ page 19 – Remove bolts -2- and remove bonnet hinge -1-. 1.6.2 Installing – Install flap hinge -1-. – Specified torque for bolts -2-: 22 Nm.

  • Page 30: Removing And Installing Insulation

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing insulation 1.7.1 Removing – Lever retaining clips -1- (Qty. 10) out of insulation -2- using removal lever -80-200- . – Pull insulation -2- out of elongated holes.
  • Page 31 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.7.2 Installing – Push insulation -2- underneath gas strut and place assembly tongues in elongated holes. – Engage all retaining clips -1- (Qty. 10) in insulation -2-. • When installing insulation -2- ensure that retaining clips -1- are fitted with wider side outwards.

  • Page 32: Assembly Overview - Bonnet Latch And Release Components

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bonnet latch and release components 1 - Arrester ❑ Removing: – Remove bolts -2- and remove latch hook. ❑ Adjusting: – Adjustment is carried out by moving arrester to left or right in elonga‐...

  • Page 33: Removing And Installing Bonnet Lock

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing bonnet lock 1.9.1 Removing – Open bonnet. Depending on model – Remove radiator grille ⇒ page 230 – Remove GTI radiator grille ⇒ page 233 – Remove R32 radiator grille ⇒...

  • Page 34: Separating Bowden Cable

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.10 Separating Bowden cable – Open bonnet. – Unclip Bowden coupling -1- above headlight on driver side of lock carrier -2-. – Open Bowden cable coupling -1- upwards and remove Bow‐...
  • Page 35 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove arrester -9- ⇒ Item 1 (page 24) – Disconnect gas strut -2- at bonnet -1- ⇒ page 20 – By loosening hexagon nuts -5- and bolt -3- on both bonnet hinges -4- (do not remove) the bonnet -1- can be aligned be‐...

  • Page 36: Removing And Installing Release Lever

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.12 Removing and installing release lever 1.12.1 Removing – Pull release lever -1- and release bonnet. – Insert a small screwdriver in gap between release lever -1- and clip -2-.

  • Page 37: Rear Lid

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear lid Tools Special tools and workshop equipment required ♦ Torque wrench 5...50 Nm -V.A.G 1331- Assembly overview - rear lid 1 - Lid ❑ Removing and installing ⇒ page 30 ❑...

  • Page 38: Removing And Installing Rear Lid

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing rear lid 2.3.1 Removing – Open rear lid -1-. – Remove rear lid trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Trims and insulation; Rear lid trim .

  • Page 39: Removing Gas Strut

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Specified torque for rear lid bolts: 10 Nm. – Adjusting lid ⇒ page 34 • Before closing rear lid, check function of lid release compo‐ nents. Removing gas strut –...
  • Page 40 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.6.1 Removing – Remove rear lid -1- ⇒ page 30 – Lower rear of moulded headlining ⇒ General body repairs, interior; Rep. Gr. 70 ; Trims, insulation; Roof trims; Removing and installing moulded headlining .
  • Page 41 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.6.2 Installing Note After installing rear lid -1- tighten hexagon nut -3- for rear lid hinge -2- again to 24 Nm. – Install rear lid hinge -2- and tighten hexagon nut -3- to 24 Nm.

  • Page 42: Removing And Installing Striker Pin

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing striker pin 2.7.1 Removing – Remove lock carrier cover ⇒ General body repairs, interior; Rep. Gr. 70 ; Luggage and load area compartment trim; Re‐ moving and installing lock carrier cover .
  • Page 43 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Adjust adjustment buffer ⇒ page 35 Note The lid is adjusted correctly if the gaps/shut lines are even all around, the lid is not too deep or too high and all contours align when the lid closed.
  • Page 44 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Adjust detent slide to dimension -a = 12.5 mm-. – Close rear lid to detent position with light pressure at centre of lid. – Open rear lid again. – Screw in adjustment buffer clamping screw -1- to a depth of dimension -a = 25 mm-.

  • Page 45: Assembly Overview - Rear Lid Latch And Release Components

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - rear lid latch and release components 1 - Release element with but‐ ton E234 ❑ Removing and installing ⇒ page 37 2 - Bolt ❑ Qty. 5 ❑...
  • Page 46 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.10.1 Removing – Remove rear lid trim ⇒ General body repairs, interior; Rep. Gr. 70; ; Trims and insulation; Rear lid trim . – Remove rear window wiper motor ⇒ Electrical system; Rep.

  • Page 47: Removing And Installing Lid Lock

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.11 Removing and installing lid lock Note If rear lid will not open, it can be opened by hand using the emer‐ gency release -1- on rear lid lock -2-. Emergency release can be found through an aperture in the rear lid trim 2.11.1...

  • Page 48: Removing And Installing Rear Lid Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note 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 leak-free tight seal is not guaranteed.

  • Page 49: Tank Flap Unit

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Tank flap unit Tools Special tools and workshop equipment required ♦ Socket -T 10010- Assembly overview - tank flap unit 1 - Tank flap unit ❑ Removing ⇒ page 42 2 - Bolt ❑...
  • Page 50 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.2.1 Removing tank flap unit Note If the fuel tank filler flap does not open, open by hand using the release rod -5-. The side trim must be removed to do this.
  • Page 51 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.2.2 Installing tank flap unit • The mounting part -4- has been pushed in. – Pass drain hose -3- through the opening in tank flap unit and pull hose through as far as possible.
  • Page 52 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.2.3 Removing actuator – Remove luggage compartment side panel trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Trims, insulation; Luggage and load compartment trims . – Disconnect connector on actuator -7-.

  • Page 53: Front Doors, Door Components, Central Locking

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 57 – Front doors, door components, central locking Front door Tools Special tools and workshop equipment required ♦ Socket -T 10072- ♦ Assembly tool -T 10118- ♦ Door alignment tool -3320- ♦...

  • Page 54: Materials

    4) Folding cardboard carton with 10 sheets each with 15 adhesive strips. Assembly overview - door assembly A new door concept has been introduced with Golf 2004. The door consists of a door inner part -6- and door outer panel -1-.
  • Page 55 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 The parts are joined by the front -7- and rear -5- retaining rails. The retaining rails are bolted to the door inner part and bonded to the door outer panel.

  • Page 56: Assembly Overview - Door Hinges

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 ❑ 10 Nm 9 - Insulation ❑ Self-adhesive ❑ To bond, first heat the insulation and then press on firmly 10 - Clip ❑ Qty. 6 11 - Window slot seal ❑...
  • Page 57 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note The right side is shown. The left side is similar. ♦ The hinge bolts must always be renewed if loosened. ♦ Hinges are now one piece. ♦ The specified torque for the hinge bolts to the door (bolts -4, 6 and 14-) has been revised.

  • Page 58: Removing And Installing Door

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 11 - Door hinge ❑ Door hinge no longer comprises of more than one part 12 - Multi-point socket head bolt ❑ 20 Nm + / 4 turn further (90°).
  • Page 59 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.5.1 Removing – Release bellows -6- by pressing the catch -arrow a- and pull bellows off A-pillar. – Swing release lever -7- downwards -arrow b- and disconnect electrical connector -8- from coupling station.

  • Page 60: Adjusting Door

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Adjusting door Note The door is adjusted correctly if the gaps/shut lines are even ♦ all around, the door is not too deep or does not stand proud and all contours align when the is door closed.
  • Page 61 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Note front door gap dimensions ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions . Adjustments are carried out using eccentric pin -7-. Other measures such as raising the door have no effect. Subse‐...
  • Page 62 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.6.2 Adjusting door fittings for flushness Use bolts -2, 3, 4, 5 and 6- on hinge to adjust correctly for flush‐ ness. Use door alignment tool -3320- with bit -3320/3- .

  • Page 63: Removing And Installing Door Outer Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing door outer pan‐ 1.7.1 Removing – Lever out clips-3- from the bottom starting on the door -1- and remove cover -2-. 1. Front door...
  • Page 64 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove lock cylinder ⇒ page 67 – Remove door handle ⇒ page 68 – Remove bolt -1- from mounting bracket -2- which is located behind door outer panel. – Remove all bolts -2, 3 and 4-.
  • Page 65 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.7.2 Installing Caution Bolts of different types are used to secure door outer panel. If these are fitted in the wrong positions, the door outer panel will be damaged. – Carefully fit door outer panel.

  • Page 66: Installing New Outer Panel For Door

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • Observe correct specified torque for the different types of bolts. Specified torque for bolt -2-: 10 Nm. Specified torque for bolt -3-: 14 Nm. Specified torque for bolt -4-: 10 Nm.
  • Page 67 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • The old (damaged) door outer panel with retaining rails is re‐ moved ⇒ page 55 – Install front -2- and rear -6- retaining rails to door inner part. For this use “bolt without point with thick washer”.
  • Page 68 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Place door outer panel with assembly blocks on surrounding components -2 and 5-. – Check gap dimension using setting gauge -3371- ⇒ Body Re‐ pairs; Rep. Gr. 00 ; Technical data; Body gap dimensions .
  • Page 69 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Use fixing block from assembly tool set T10237 to insert door outer panel. Two strips of “Tesa Power Strips large” -5- are bon‐ ded to the contact surfaces. – Guide door outer panel -1- over guide bolts in lower edge of door inner part.

  • Page 70: Removing And Installing Retaining Rail On Door Outer Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing retaining rail on door outer panel 1.9.1 Removing retaining rail Caution The following work steps are to be carried out with great care. As door outer skin is to be reused, dents and scratches must be avoided.

  • Page 71: Installation Instructions For Bonding In New Door Outer Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Once adhesive bead has been cut through to just over half way in step one, turn reel device -2- around and insert cord -5- in side still bonded. – Hold retaining rail -3- and outer skin -1- together securely when cutting through adhesive bead further.

  • Page 72: Minimum Curing Period

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Clean contact surfaces on retaining rails thoroughly using cleaning solution D 009 401 04. – Apply adhesive material to appropriate surfaces at right angles to retaining rail using cartridge gun -V.A.G 1628- .

  • Page 73: Assembly Overview - Door Inner Part

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – First clean painted surface as much as possible using a dry cloth. Remove remaining adhesive with adhesive remover D 002 000 10. – Cleaning plastic trim: allow adhesive sealant to cure (approx.

  • Page 74: Assembly Overview - Door Handle And Door Lock

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.14 Assembly overview - door handle and door lock Note Only the left side is shown. The procedure for the right side is similar. 1 - Door lock ❑ Removing and installing ⇒...

  • Page 75: Removing And Installing Housing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 15 - Retaining bracket ❑ Not installed on Golf 16 - Cable ❑ To release lock from inner door handle 17 - Cover ❑ Not supplied as part of door lock ❑...

  • Page 76: Removing And Installing Door Handle

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.16 Removing and installing door handle Note The removal and installation sequence is only for the right door handle. The removal and installation of the left door handle is similar.
  • Page 77 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.16.2 Installing – Guide assembly tool -T 10118- into door through opening in door inner panel. – Use a hand torch to illuminate inside of door for improved vis‐ ibility.

  • Page 78: Removing And Installing Mounting Plate

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Swivel door handle -1- into door. – Pull clip -2- in the panel opening and engage clip in door han‐ dle -1- -arrow-. Note Door handle -1- must be pressed against door panel when ♦...
  • Page 79 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.17.1 Removing – Remove lock cylinder housing ⇒ page 67 – Remove door handle ⇒ page 68 – Remove door outer panel ⇒ page 94 – Pull retaining rubber -4- upwards off guide pins.

  • Page 80: Removing And Installing Door Lock

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.17.2 Installing – Push mounting plate -1- with guide pins -2- in mounting -3-. – Secure retaining rubber -4- to guide pins and securing bolts on mounting plate support. Further installation is performed in the reverse order of removal.
  • Page 81 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.18.1 Removing – Remove door outer panel ⇒ page 94 – Remove mounting plate ⇒ page 70 – Disconnect connector -5-. – Remove bolts -6-. – Release cable -1- from relay lever -8- and remove door lock -4-.

  • Page 82: Assembly Overview - Side Impact Protection

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.19 Assembly overview - side impact pro‐ tection Caution The nuts and bolts of the side impact protection are also pain‐ ted in the factory. This means that a great deal of force is required to remove them, resulting in some circumstances in the threads shearing.

  • Page 83: Removing And Installing Door Inner Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note 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 leak-free tight seal is not guaranteed.
  • Page 84 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Pull door inner seal off body flange. 1.21.2 Installing – Align door inner seal with vulcanisation point -arrow b- to height of lower hinge. – Begin installing door inner seal in upper radius -arrow a- of door aperture.

  • Page 85: Removing And Installing Door Outer Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22 Removing and installing door outer seal Note Removal and installation are described for the right door outer ♦ seal only. Removal and installation of the left door outer seal are similar.
  • Page 86 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22.2 Installing – Remove existing adhesive residues with adhesive remains re‐ mover -VAS 6349- . – Immediately before bonding the door outer seal, clean bond‐ ing surface thoroughly with adhesive remover D 002 000 10.
  • Page 87 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Press complete adhesive area of seal -3- on door -1- all around using roller -3356- . – The seal is pushed aside -arrow a- when doing this so that the roller -3356- runs directly over the contact surface of the seal.

  • Page 88: Central Locking

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Central locking Location overview - central locking components 1 - Coupling station ❑ Location: right-hand A- pillar ❑ To disconnect connec‐ tor, release boot at pillar ⇒ page 51 2 - Convenience system cen‐...

  • Page 89: Adapting Keys With Remote Control

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 ❑ Removing ⇒ page 44 10 - Rear lid lock ❑ Fitting location: bolted to rear lid. ❑ Removing ⇒ page 39 11 - Release element with button ❑ Fitting location: bolted in rear lid.

  • Page 90: Assembly Overview - Battery For Folding Key With Remote Control

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Select “guided fault finding” in diagnostic tester -VAS 5051 A- . – Using the “GoTo” key, select "Function/component selection" and the following menu items one after the other: ♦ Body ♦...

  • Page 91: Removing And Installing Battery For Folding Key With Remote Control

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing battery for fold‐ ing key with remote control 2.4.1 Removing – Insert a screwdriver in slot between transmitter unit -1- and key -2-. – Twist screwdriver in -direction of arrow- to separate transmitter unit from key.
  • Page 92 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note polarity and correct position when installing battery. – Lay battery -1- with positive terminal downwards in sender unit -2- (positive terminal is marked on housing). – Engage battery in transmitter body by pressing down lightly.

  • Page 93: Rear Doors, Door Components

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 58 – Rear doors, door components Rear door Tools Special tools and workshop equipment required ♦ Socket -T 10072- ♦ Assembly tool -T 10118- ♦ Door alignment tool -3320- ♦ Universal joint for 3320 -3320/1- ♦...

  • Page 94: Materials

    8) Folding cardboard carton with 10 sheets each with 15 adhesive strips. Assembly overview - door assembly A new door concept has been introduced with Golf 2004. The door consists of a door inner part -6- and door outer panel -1-.
  • Page 95 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 The parts are joined by the front -7- and rear -4- retaining rails. The retaining rails are bolted to the door inner part and bonded to the door outer panel.

  • Page 96: Assembly Overview - Door Hinges

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - door hinges Caution Bolt of eccentric pin -10- should not be loosened under any circumstances on vehicles up to 01.2004. It cannot be tight‐ ened again using normal workshop tools.

  • Page 97: Removing And Installing Door

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 8 - Guide bolt ❑ 10 Nm 9 - Adjustment ring ❑ Restricts the adjustment range for the eccentric pin 10 - Bolt ❑ 28 Nm ❑ For eccentric pin 11 - Door hinge ❑...
  • Page 98 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.5.1 Removing – Release bellows -6- by pressing catch -arrow a- and pull bel‐ lows off B-pillar. – Swing release lever -7- downwards -arrow b- and disconnect electrical connector -8- from coupling station.

  • Page 99: Adjusting Door

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Adjusting door Note The door is adjusted correctly if the gaps/shut lines are even ♦ all around, the door is not too deep or does not stand proud and all contours align when the is door closed.
  • Page 100 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Note front door gap dimensions ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions . Adjustments are carried out using eccentric pin -7-. Other measures such as raising the door have no effect. Subse‐...
  • Page 101 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.6.2 Adjusting door fittings for flushness Use bolts -2, 3, 4, 5 and 6- on hinge to adjust correctly for flush‐ ness. Use door alignment tool -3320- with bit -3320/3- .

  • Page 102: Removing And Installing Door Outer Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing door outer pan‐ 1.7.1 Removing – Lever out clips -3- from the bottom starting on the door -1- and remove rear cover -2-. – Lever out clips -5- from the bottom starting on the door -1- and remove rear cover -4-.
  • Page 103 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove lock cylinder housing: ⇒ page 67 – Remove door handle ⇒ page 68 – Remove bolt -1- from mounting bracket -2- which is located behind door outer panel.
  • Page 104 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.7.2 Installing Caution Bolts of different types are used to secure door outer panel. If these are fitted in the wrong positions, the door outer skin will be damaged. – Carefully fit door outer panel.

  • Page 105: Installing New Outer Panel For Door

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • Observe correct specified torque for the different types of bolts. Specified torque for bolt -2-: 10 Nm. Specified torque for bolt -3-: 14 Nm. Specified torque for bolt -4-: 10 Nm.
  • Page 106 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • The old (damaged) door outer panel with retaining rails is re‐ moved ⇒ page 94 – Install front -2- and rear -6- retaining rails to door inner part. For this use “bolt without point with thick washer”.
  • Page 107 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Place door outer panel with assembly blocks on surrounding components -2 and 5-. – Check gap dimension using setting gauge -3371- ⇒ Body Re‐ pairs; Rep. Gr. 00 ; Technical data; Body gap dimensions .
  • Page 108 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 To fit door outer panel, assembly block from assembly tool set - T 10237- is required. Two strips of “Tesa Power Strips large” -5- are bonded to the contact surfaces.

  • Page 109: Removing And Installing Retaining Rail On Door Outer Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing retaining rail on door outer panel 1.9.1 Removing retaining rail Caution The following work steps are to be carried out with great care. As door outer skin is to be reused, dents and scratches must be avoided.

  • Page 110: Installation Instructions For Bonding In New Door Outer Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Once adhesive bead has been cut through to just over half way in step one, turn reel device -2- around and insert cord -5- in side still bonded. – Hold retaining rail -3- and outer skin -1- together securely when cutting through adhesive bead further.

  • Page 111: Minimum Curing Period

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Apply adhesive material to appropriate surfaces at right angles to retaining rail using cartridge gun -V.A.G 1628- . WARNING Door outer panel must be installed within 10 minutes, or ad‐...

  • Page 112: Assembly Overview - Door Inner Part

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Cleaning plastic trim: allow adhesive sealant to cure (approx. one hour) and then peel off. 1.13 Assembly overview - door inner part Note The right side is shown. The left side is similar.

  • Page 113: Assembly Overview - Door Handle And Door Lock

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.14 Assembly overview - door handle and door lock Note The right side is shown. The left side is similar. 1 - Door lock ❑ Door lock can only be...

  • Page 114: Removing And Installing Housing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 15 - Cable ❑ To release lock from outer door handle 1.15 Removing and installing housing Note Removal and installation sequence is only for right housing. Re‐ moval and installation of left housing is similar.
  • Page 115 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.16.1 Removing – Remove housing ⇒ page 106 – Lever clip -2- out of door handle -1-. – Swivel door handle -1- out of door -arrow-. 1.16.2 Installing – Guide assembly tool -T 10118- into door through opening in door inner panel.

  • Page 116: Removing Bearing Bracket

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Hook spring into door lock by pulling assembly tool -T 10118- -arrow B-. The release lever is now secured. – Swivel door handle -1- into door. – Pull clip -2- in the panel opening and engage clip in door han‐...
  • Page 117 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.17.1 Removing – Remove housing ⇒ page 106 – Remove door handle: ⇒ page 106 – Remove door outer panel: ⇒ page 94 – Pull retaining rubber -4- off upwards from guide pins and re‐...

  • Page 118: Removing And Installing Door Lock

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.17.2 Installing – Push mounting plate -1- with guide pins -2- in mounting -3-. – Secure retaining rubber -4- to guide pins and securing pins on mounting. 1.18 Removing and installing door lock...

  • Page 119: Assembly Overview - Side Impact Protection

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.18.1 Removing – Remove door outer panel ⇒ page 94 – Remove mounting plate ⇒ page 108 – Separate connector -4-. – Remove bolts -6-. – Release cable -3- from relay lever -5- and remove door lock -1-.

  • Page 120: Door Inner Seals

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1 - Side impact protection 2 - Bolts ❑ Qty. 2 ❑ 20 Nm 3 - Nut ❑ Qty. 2 ❑ 20 Nm 4 - Door inner part 1.20 Door inner seals During production, a sealant is applied to the door inner seals, which are then placed on the door flange and rolled on.

  • Page 121: Removing And Installing Door Inner Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.21 Removing and installing door inner seal Note The removal and installation sequence is only for the right door inner seal. The removal and installation of the left door inner seal is similar.

  • Page 122: Removing And Installing Door Outer Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.21.2 Installing – Align door inner seal with vulcanisation point -arrow b- to height of lower hinge. – Begin installing door inner seal in upper radius -arrow a- of door aperture.
  • Page 123 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22.1 Removing – Pull door outer seal -1- from door -2-. 1. Rear door...
  • Page 124 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22.2 Installing – Remove existing adhesive residues with adhesive remains re‐ mover -VAS 6349- . – Immediately before bonding the door outer seal, clean bond‐ ing surface thoroughly with adhesive remover D 002 000 10.
  • Page 125 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Press complete adhesive area of seal -3- on door -1- all around using roller -3356- . – The seal is pushed aside -arrow a- when doing this so that the roller -3356- runs directly over the contact surface of the seal.

  • Page 126: Sunroof

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 60 – Sunroof Sliding/tilting sunroof with glass pan‐ el (Meritor) Tools 1.1.1 Required special tools, workshop equip‐ ment, test and measuring devices and auxiliary items ♦ Roller -3356- ♦ Hooks for front end -3370- ♦...

  • Page 127: Function

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Function All actions of the sunroof with glass panel can be performed with the ignition switched on. After the ignition is switched off, actions can be performed until either the driver or front passenger door is opened.

  • Page 128: Assembly Overview - Sliding/Tilting Sunroof With Glass Panel

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - sliding/tilting sunroof with glass panel 1 - Glass panel for sliding/tilting sunroof (single pane safety glass) ❑ Removing glass panel of sliding/tilting sunroof ⇒ page 123 ❑ Installing glass panel of sliding/tilting sunroof ⇒...
  • Page 129 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 ❑ To seal use butyl adhesive sealing cord -AKL 450 005 05- 11 - Carrier unit ❑ Removing and installing carrier unit ⇒ page 132 ❑ If necessary, guide channels should be lubricated only with special grease G 000 450 02, otherwise...

  • Page 130: Removing And Installing Bellows

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing bellows 1.4.1 Removing – Move sliding headliner to rear. – Run sliding/tilting sunroof glass panel to tilted position. – Carefully unclip bellows -1- from lower part of guide plate -3- using a removal wedge -3409- .

  • Page 131: Removing Glass Panel Of Sliding/Tilting Sunroof

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.4.2 Installing – Move sliding headliner to rear. – Run sliding/tilting sunroof glass panel to tilted position. – Fit bellows -1- first at top rear -2-. – Clip bellows -1- with securing pins -4- in guide plate.

  • Page 132: Installing Glass Panel Of Sliding/Tilting Sunroof

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove bolts -1- on left and right. – Remove sliding/tilting sunroof glass panel -2- out upwards. WARNING The guide plate must not moved to “Open” position when re‐ moved, because the water channel will not be compressed by the glass panel and can become wedged together in the roof.

  • Page 133: Adjusting Panel Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove bellows: ⇒ page 122 – Remove sliding/tilting sunroof glass panel -2- securing bolts -1-. – Run sliding/tilting sunroof glass panel to “open” position. – Run sliding/tilting sunroof glass panel to “closed” position.

  • Page 134: Renewing Panel Seal

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – If preload is too great press panel seal -1- together all-round with roller -3356- . Renewing panel seal – Remove glass panel of sliding/tilting sunroof ⇒ page 123 – Pull seal -1- off sliding/tilting sunroof glass panel -2-.

  • Page 135: Removing And Installing Sliding Headliner

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Push wind deflector and height limit stop out at front of roof aperture and set wind deflector to vertical position. – Place special tool front-end hook -3370- between edge of roof and wind deflector bearing -arrow-.

  • Page 136: Removing And Installing Sliding/Tilting Sunroof Glass Panel Drive

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Slide sliding headlining a little to rear. – Remove front bolts -arrow- on left and right. Push spring slide forwards past the stop -1-. – Push sliding headlining forwards and lift it slightly past end of roof aperture.

  • Page 137: Adjusting Drive For Sliding/Tilting Sunroof Glass Panel (0 Position)

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 WARNING Remove or install drive for tilting/sliding sunroof glass panel only when sunroof is closed (0 position ). The requirements for removing and installing drive are: Engine not running and ignition off, key not in ignition and door open.

  • Page 138: Removing And Installing Sliding/Tilting Sunroof Glass Panel Automatic Preselection Switch

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • The sliding/tilting sunroof glass panel drive is in 0 position, if a white dot can be seen in the drive aperture -arrow-. 1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselec‐...

  • Page 139: Assembly Overview - Carrier Unit

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 The mark -arrow- on the rear of the guide upper section -1- must, on both sides, lie within the marks dimension -a- on the guide plate -2-. The guide plate -2- must be located in the guide rails (cannot be moved by hand).

  • Page 140: Removing And Installing Carrier Unit

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.18 Removing and installing carrier unit WARNING Remove or install drive for tilting/sliding sunroof glass panel only when sunroof is closed (0 position ). The requirements for removing and installing drive are: Engine not running and ignition off, key not in ignition and door open.
  • Page 141 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.18.2 Installing – Fit carrier unit -1- into roof aperture with the help of a second mechanic. – During installation, align carrier unit -1- in roof via two cylin‐ drical pins (shank end of drill) 12 mm front right -arrow- and 10 mm rear left -arrow-.

  • Page 142: Operating Without Electrics

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.19 Operating without electrics Note In the event of power failure, the sliding/tilting sunroof with glass panel can be moved using a hexagon key directly on the drive. Hexagon key (crank) is housed in moulded headliner on right next to opening for rear interior light and reading lamp.

  • Page 143: Removing And Installing Sliding Gate

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Slide front guide -2- forwards and pull guide plate -1- in -direction of arrow- out of front guide -2-. 1.20.2 Installing Installation is carried out in reverse order of removal.

  • Page 144: Cleaning Water Drain Hoses

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Slide rear guide lower part -1- in -direction of arrow- in guide rail -3-, until the locating hook guide locking mechanism -2- is released. – Pull out rear guide lower part -1- and locking hook guide -2- together in -direction of arrow- from guide rail -3- and remove.
  • Page 145 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22.1 Front water drain hoses The front water drain hoses run through the A-pillars and end at the bulkhead cross member. Cleaning is done from the sunroof panel aperture. 1. Sliding/tilting sunroof with glass panel (Meritor)
  • Page 146 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22.2 Rear water drain hoses The rear water drain hoses run through the C-pillars and end in the rear wheel housings. Cleaning is done from the wheel hous‐ ing. The wheel housing liner must be removed.

  • Page 147: Bumpers

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 63 – Bumpers Front bumper Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1332- Repairing bumper cover Note If bumper cover is damaged, determine whether plastic can be repaired before renewing bumper Details can be found under: ⇒...

  • Page 148: Assembly Overview - Bumper Cover

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bumper cover 1 - Cover ❑ Material PP/EPDM ❑ Removing and installing ⇒ page 140 2 - Bolt ❑ 1.5 Nm 3 - Bolt ❑ Qty. 4 per side.
  • Page 149 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.4.1 Removing – Remove radiator grille ⇒ page 230 – Remove bolts -5- and -6-. – Remove bolts -4- from below. – Remove bolts -3- and -2- (point upwards) on left and right in area of wheel housing liner.

  • Page 150: Front Bumper Attachments

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Ensure that gaps are parallel and specified dimensions are maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions . Front bumper attachments Note Minor differences will be encountered on removal and installing, depending on version.

  • Page 151: Front Bumper Substructure

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 10 - Right air intake grille ❑ Remove bolt -8- and pull forwards out of fastening in -direction of arrow- 11 - Clip ❑ For separate number plate carrier ❑ Qty. 4 12 - Number plate carrier ❑...

  • Page 152: Assembly Overview - Bumper Carrier

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bumper carrier 1 - Bumper carrier 2 - Bolt ❑ Qty. 4 per side. ❑ 60 Nm 3 - Bolt ❑ Qty. 6 ❑ 8 Nm 4 - Foam piece ❑...

  • Page 153: Assembly Overview - Number Plate Carrier

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - number plate carrier 1 - Bumper cover 2 - Number plate carrier ❑ Not for all countries ❑ Installing – Align number plate car‐ rier -3-, mark position of holes and drill-out –...

  • Page 154: Front Bumper For Gti, Gti Special Models, Gt, R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Front bumper for GTI, GTI special models, GT, R32 Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1332- Repairing bumper cover Note...

  • Page 155: Removing And Installing Front Bumper Cover For Gt, Gti

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1 - Cover ❑ Material PP/EPDM ❑ Removing and installing ⇒ page 147 2 - Bolt ❑ 1.5 Nm 3 - Bolt ❑ Qty. 4 per side. ❑ 2 Nm 4 - Bolt ❑...
  • Page 156 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.4.1 Removing – Remove radiator grille ⇒ page 233 – Remove bolts -5-. – Remove bolts -4- from below. – Remove bolts -3- and -2- (point upwards) on left and right in area of wheel housing liner.

  • Page 157: Front Bumper Attachments For Gt, Gti

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Front bumper attachments for GT, GTI Note Minor differences will be encountered on removal and instal‐ ♦ ling, depending on version. The bumper covers of the Golf GT and Golf GTI are identical.
  • Page 158 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 8 - Bolt ❑ Qty. 7 ❑ 1.5 Nm 9 - Centre air intake grille ❑ Different appearance for Golf GT and Golf GTI ❑ Can only be removed when the radiator grille is removed ❑...

  • Page 159: Assembly Overview - Bumper Cover For R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bumper cover for R32 Note Minor differences may be encountered in the assembly overview depending on version. 1 - Cover ❑ Material PP/EPDM ❑ Removing and installing ⇒...
  • Page 160 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.7.1 Removing – Remove radiator grille ⇒ page 237 – Remove bolts -5-. – Remove bolts -4- from below. – Remove bolts -3- and -2- (point upwards) on left and right in area of wheel housing liner.

  • Page 161: Front Bumper Attachments For R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Ensure that gaps are parallel and specified dimensions are maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions . Front bumper attachments for R32 Note Minor differences will be encountered on removal and installing, depending on version.

  • Page 162: Assembly Overview - Front Bumper Cover For Gti Special Models

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - front bumper cover for GTI special models Note Minor differences may be encountered in the assembly overview depending on version. 1 - Cover ❑ Material: PP/EPDM PU- ❑...
  • Page 163 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.10.1 Removing – Remove radiator grille ⇒ page 233 – Remove bolts -5- from above. – Remove bolts -4- from below. – Remove bolts -3- and -2- (point upwards) on left and right in area of wheel housing liner.

  • Page 164: Front Bumper Attachments For Gti Special Models

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.11 Front bumper attachments for GTI special models Note Minor differences will be encountered on removal and installing, depending on version. 1 - Cover ❑ Material: PP/EPDM PU- ❑ Removing and installing ⇒...

  • Page 165: Front Bumper Substructure

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.12 Front bumper substructure 1 - Left air duct ❑ Engages in lock carrier. 2 - Left guide ❑ Bolted to lock carrier. 3 - Bolt ❑ Qty. 2 per retainer.

  • Page 166: Assembly Overview - Bumper Carrier

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.13 Assembly overview - bumper carrier 1 - Bumper carrier 2 - Bolt ❑ Qty. 4 per side. ❑ 60 Nm 3 - Bolt ❑ Qty. 6 ❑ 8 Nm 4 - Foam piece ❑...

  • Page 167: Rear Bumper

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear bumper Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1331- Repairing bumper cover Note If bumper cover is damaged, determine whether plastic can be repaired before renewing bumper Details can be found under: ⇒...

  • Page 168: Assembly Overview - Bumper Cover

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bumper cover 1 - Cover ❑ Material PP/EPDM ❑ Removing and installing ⇒ page 160 2 - Bolt ❑ Qty. 2 ❑ 5 Nm 3 - Bolt ❑...
  • Page 169 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.4.1 Removing – Remove tail lights ⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - exterior; Removing and installing tail lights . – Remove bolts -5- on left and right in area of wheel housing liner.

  • Page 170: Rear Bumper Attachments

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.4.2 Installing Installation is carried out in reverse order of removal. – Ensure that gaps are parallel and specified dimensions are maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technical data;...

  • Page 171: Rear Bumper Substructure

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear bumper substructure 1 - Securing strip 2 - Hexagon nut ❑ Qty. 4 ❑ 2 Nm 3 - Guide ❑ Left and right 4 - Hexagon nut ❑ Qty. 3 per side ❑...

  • Page 172: Assembly Overview - Bumper Carrier

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bumper carrier 1 - Cross member 2 - Bolt ❑ Qty. 6 ❑ 20 Nm 3 - Foam piece ❑ Only installed in some countries ❑ Self-adhesive ❑...
  • Page 173 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1 - Towing bracket ❑ Towing bracket with re‐ movable ball head is shown in illustration 2 - Ball hitch ❑ The removable ball head is located in the left...

  • Page 174: Rear Bumper For R32 And Gti Special Models

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear bumper for R32 and GTI special models Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1332- Repairing bumper cover Note If bumper cover is damaged, determine whether plastic can be repaired before renewing bumper Details can be found under: ⇒...

  • Page 175: Assembly Overview - Bumper Cover For R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - bumper cover for R32 Note Minor differences may be encountered in the assembly overview depending on version. 1 - Cover ❑ With various forms for number plate ❑...
  • Page 176 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.4.1 Removing – Remove tail lights ⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - exterior; Removing and installing tail lights . – Remove bolts -4- on left and right in area of wheel housing liner.

  • Page 177: Rear Bumper Attachments For R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Ensure that gaps are parallel and specified dimensions are maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body gap dimensions . Rear bumper attachments for R32 Note Minor differences will be encountered on removal and installing, depending on version.

  • Page 178: Assembly Overview - Rear Bumper Cover For Gti Special Models

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - rear bumper cover for GTI special models Note Minor differences may be encountered in the assembly overview depending on version. 1 - Cover ❑ Material: PP/EPDM PU- ❑...
  • Page 179 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.7.1 Removing – Remove tail lights ⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - exterior; Removing and installing tail lights . – Remove bolts -4- on left and right in area of wheel housing liner.

  • Page 180: Rear Bumper Attachments For Gti Special Models

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Ensure that gaps are parallel and specified dimensions are maintained ⇒ Body Repairs; Rep. Gr. 00 ; Technical data; Body panel gaps/shut lines . Rear bumper attachments for GTI special models Note Minor differences will be encountered on removal and installing, depending on version.

  • Page 181: Rear Bumper Substructure

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear bumper substructure 1 - Securing strip 2 - Hexagon nut ❑ Qty. 4 ❑ 2 Nm 3 - Guide ❑ Left and right 4 - Hexagon nut ❑ Qty. 3 per side ❑...

  • Page 182: Assembly Overview - Bumper Carrier

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.10 Assembly overview - bumper carrier Note Minor differences will be encountered on removal and installing, depending on version. 1 - Cross member 2 - Bolt ❑ Qty. 6 ❑ 20 Nm 3 - Foam piece ❑...

  • Page 183: Glazing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 64 – Glazing Flush bonded windows Tools Special tools and workshop equipment required ♦ Removal kit for flush bonded windows -V.A.G 1474 A- ♦ Suction lifter -V.A.G 1344- ♦ Cutting tool -V.A.G 1351- ♦...

  • Page 184: Golf

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 ♦ Scraping blade -V.A.G 1561/8- ♦ Cutting blade -V.A.G 1561/10- ♦ Cutting blade -V.A.G 1561/19- ♦ Double cartridge gun -VAS 5237- Rep. Gr.64 - Glazing...

  • Page 185: Materials

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Materials ♦ 2K window adhesive DA 004 600 A2 10) 12) ♦ 1K window adhesive DH 009 100 03 13) 11) ♦ Activator D 181 801 A1 ♦ Glass primer/paint primer D 009 200 02 ♦...

  • Page 186: Assembly Overview - Windscreen

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - windscreen 1 - Windscreen ❑ Removing ⇒ page 182 ❑ Installing ⇒ page 182 2 - Windscreen adjuster ❑ 443 845 631 A 3 - Plenum chamber cover ❑...

  • Page 187: Assembly Overview - Plenum Chamber Cover

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - plenum chamber cover 1 - Plenum chamber cover ❑ Must be removed from windscreen seal by hand only ❑ Removing ⇒ page 180 ❑ Installing ⇒ page 181...
  • Page 188 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.5.1 Removing plenum chamber cover – Unbolt wiper arms ⇒ Electrical system; Rep. Gr. 92 ; Wind‐ screen wiper system; Removing and installing windscreen wiper system; Removing and installing wiper arms .
  • Page 189 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.5.2 Installing plenum chamber cover WARNING Striking the plenum chamber cover can cause cracks in the windscreen. – Spray windscreen seal -5- with a soapy solution so that ple‐ num chamber cover -1- is easier to press on.

  • Page 190: Removing Windscreen

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing windscreen – Remove A-pillar trims ⇒ General body repairs, interior; Rep. Gr. 70 ; Trims, insulation; Pillars and side trims . – Remove left and right sun visors ⇒ General body repairs, in‐...

  • Page 191: Assembly Overview - Rear Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Minimum curing period ⇒ page 191 Assembly overview - rear window 1 - Rear window ❑ Removing ⇒ page 183 ❑ Installing ⇒ page 185 2 - Seal ❑ For rear window wiper...

  • Page 192: Removing Broken Rear Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Pull off connections -1- on left and right for heated rear window and window aerial. – Thrust awl -V.A.G 1474/2- -1- through adhesive bead. – Pull cutting cord -2- through adhesive sealing material to in‐...

  • Page 193: Installing Rear Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Apply textile reinforced adhesive tape all around flange -1-. – Cut through adhesive sealing material (with pieces of glass) in window aperture using electric cutter -V.A.G 1561 A- -3- and cutting blade -V.A.G 1561/10 - -2-.

  • Page 194: Assembly Overview - Rear Side Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.12 Assembly overview - rear side window 1 - Side window ❑ Removing side window ⇒ page 186 ❑ Installing side window ⇒ page 187 2 - PUR adhesive sealant ❑...

  • Page 195: Removing Damaged Rear Side Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Secure inside end of cutting cord against falling out using pull handle -V.A.G 1351/1- -1-. – Separate sealing lip from window flange all around and spray in cleaning solution D 009 401 04 (as substitute for lubricant).

  • Page 196: Preparing Old Undamaged Window For Glazing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.16 Preparing old undamaged window for glazing Note If installing an undamaged window, cut back residual adhesive ♦ seal to 1...2 mm, being careful not to damage primer and ce‐...

  • Page 197: Preparing New Window With Precoating For Glazing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Apply primer -4- evenly in one motion using applicator D 009 500 25 -3- to the previously cleaned area -1- of window. Ensure that glass adhesive is applied to primed area at a distance of approx.

  • Page 198: Preparing Body Flange For Glazing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.19 Preparing body flange for glazing – Cut back remaining material on body flange with electric cutter -V.A.G 1561 A- and scraping blade -V.A.G 1561/8- , but do not remove completely.

  • Page 199: Installation Instructions

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.20 Installation instructions – Apply adhesive material to primed area -1- or to trimmed seal‐ ant bead, holding double cartridge gun -VAS 5237- at right angle to window. WARNING Window must be installed within 10 minutes, or adhesive prop‐...

  • Page 200: Touching Up Paint Damage

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.22 Touching up paint damage If paintwork is damage, paint structure must be restored accord‐ ing to specifications in the “Paint” workshop manual. 1.23 Cleaning off excess adhesive sealing material –...

  • Page 201: Front Door Windows

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Front door windows Tools Special tools and workshop equipment required ♦ Torque wrench 2...10 Nm -V.A.G 1783- 2. Front door windows...

  • Page 202: Assembly Overview - Front Door Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - front door window Note The right side is shown. The left side is similar. ♦ The bolt -4- is accessible from interior and exterior. From exterior the bolt has a right-hand thread. This ♦...

  • Page 203: Removing And Installing Door Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing door window Note The removal and installation sequence is only for the right door ♦ window. The removal and installation of the left door window is similar.
  • Page 204 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 WARNING Remove bolt -3- from interior by turning to right. – Loosen bolts -3- (do not remove) from inside by turning to right and press clamping jaws apart. Note If the work step cannot be carried out because there is a fault with the electric window motor, remove motor to slide window down.

  • Page 205: Adjusting Door Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Adjusting door window – Remove front door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Trim, insulation; Door trims . – Lever out caps -4-. – Lower door window -1- until clamping bolts -3- for mounting -2- are accessible.

  • Page 206: Assembly Overview - Window Regulator Motor

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Applying light pressure press door window -1- in clamping jaws in -direction of arrow- and align door window tension free at rear window guide. – When doing so, ensure that door window -1- is positioned par‐...

  • Page 207: Removing And Installing Window Regulator Motor

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing window regula‐ tor motor Note The removal and installation sequence is only for the right door ♦ window regulator. The removal and installation of the left door window regulator is similar.
  • Page 208 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Remove window regulator motor and control unit -1- from mounting plate. 2.6.2 Installing – Place window regulator motor -1- on and attach connectors -arrows-. – Move door window lightly up and down so that the splines be‐...

  • Page 209: Assembly Overview - Window Guide

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - window guide Note The right side is shown. The left side is similar. ♦ For a better representation the illustration is drawn without door outer panel. ♦...
  • Page 210 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.8.1 Removing – Remove exterior mirror ⇒ page 227 – Pull window guide -1- out of mounting. – Remove bolts -3- (Qty. 2) and pull trim plate -2- off in direction of B-pillar -direction of arrow-.

  • Page 211: Assembly Overview - Window Regulator

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - window regulator Note The right side is shown. The left side is similar. 1 - Window regulator ❑ Removing and installing ⇒ page 203 2 - Bolt ❑...
  • Page 212 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.10.1 Removing – Remove door outer panel ⇒ page 94 – Remove side impact protection ⇒ page 74 – Remove door window ⇒ page 195 – Remove bolts -2- from mounting plate -5-.

  • Page 213: Rear Door Windows

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear door windows Tools Special tools and workshop equipment required ♦ Release tool -T10236- ♦ Torque wrench 2...10 Nm -V.A.G 1783- 3. Rear door windows...

  • Page 214: Assembly Overview - Rear Door Window

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - rear door window Note The right side is shown. The left side is similar. 1 - Door window ❑ Removing and installing ⇒ page 206 2 - Window guide ❑...
  • Page 215 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.3.1 Removing – Remove rear door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Trims, insulation; Door trims . – Lever out caps -5-. – Lower door window until spreader pin -3- and spreader plug -4- are accessible in aperture of window regulator.
  • Page 216 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.3.2 Installing Note When installing door window, always renew spreader plug and ♦ spreader pin. Before inserting spreader plug and spreader pin check washer ♦ for damage. – With door window -1- removed insert spreader plug -3- in mid‐...

  • Page 217: Assembly Overview - Fixed Door Window With Window Guide

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - fixed door window with window guide 1 - Window guide ❑ Component part of fixed door window ❑ Removing and installing ⇒ page 209 2 - Fixed door window ❑...
  • Page 218 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Pull window guide -1- out of centre rib -3- and guide window guide inwards. – Remove bolts -2- and slide centre rib -3- downwards -arrow a-. – Pull centre rib -3- off fixed door window seal -arrow b-.
  • Page 219 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Pull complete window guide -1- with fixed door window -2- off window frame -3- in -direction of arrow-. 3.5.2 Installing Installation is carried out in reverse order of removal.

  • Page 220: Assembly Overview - Window Regulator Motor

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - window regulator motor Note The right side is shown. The left side is similar. 1 - Connector 2 - Bolt ❑ Qty. 3 ❑ 3.5 Nm 3 - Window regulator motor ❑...
  • Page 221 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.7.1 Removing – Removing door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Trims, insulation; Door trims . – Secure door window against sliding down with adhesive tape.
  • Page 222 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.7.2 Installing – Place window regulator motor -3- on and attach connector -1-. – Move door window lightly up and down so that the splines be‐ tween motor and cable drum engage easier.

  • Page 223: Assembly Overview - Window Regulator

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - window regulator Note The right side is shown. The left side is similar. 1 - Window regulator ❑ Removing and installing ⇒ page 215 2 - Bolt ❑...
  • Page 224 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.9.1 Removing – Remove door outer panel ⇒ page 94 – Remove impact protection ⇒ page 111 – Remove door window ⇒ page 206 – Remove bolts -2- from mounting plate -3-.

  • Page 225: Exterior Equipment

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 66 – Exterior equipment Wheel housing liner Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- 1. Wheel housing liner...

  • Page 226: Assembly Overview - Front Wheel Housing Liner

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - front wheel housing liner Note Only the left side is shown. The procedure for the right side is similar. ♦ The removal and installation procedures may have to be modified slightly depending on variations in equip‐...
  • Page 227 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.3.1 Removing Wheel housing liner rear part – Remove wheel ⇒ Running gear; Rep. Gr. 44 ; Specified tor‐ ques for wheel bolts . – Remove bolts -2- (Qty 7).

  • Page 228: Assembly Overview - Rear Wheel Housing Liner

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - rear wheel housing liner Note Only the left side is shown. The procedure for the right side is similar. 1 - Wheel housing liner ❑ Material: PP/EPDM 2 - Bolt ❑...
  • Page 229 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1.5.1 Removing – Remove wheel ⇒ Running gear; Rep. Gr. 44 ; Specified tor‐ ques for wheel bolts . – Remove bolts -2- (Qty 9). – Pull off wheel housing liner -1-.

  • Page 230: Exterior Mirror

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Exterior mirror Tools Special tools and workshop equipment required ♦ Removal lever -80-200- ♦ Torque wrench -V.A.G 1783- Rep. Gr.66 - Exterior equipment...

  • Page 231: Assembly Overview - Exterior Mirror

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - exterior mirror Note Only the left side is shown. The procedure for the right side is similar. 1 - Mirror mounting ❑ Removing and installing ⇒ page 227 2 - Bolt ❑...

  • Page 232: Removing And Installing Mirror Housing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.3.1 Removing – Protect edge of housing -1- against paint damage with e.g. fabric-reinforced adhesive tape. – Press bottom of mirror glass -2- into mirror housing -1-. – Using removal lever -80 - 200- , press mirror glass -2- off bracket -5- and housing -1- -arrow 6-.
  • Page 233 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.4.1 Removing – Remove mirror glass ⇒ page 224 – Insert removal wedge -3409- between mirror housing -1- and side turn signal -2-. – Move removal wedge -3409- in -direction of arrow a- along to outer side of mirror.

  • Page 234: Removing And Installing Trim

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.4.2 Installing – Place mirror housing -1- on mirror base carrier and press mir‐ ror housing down until the locking hooks -2- engage audibly. – Install mirror glass again ⇒ page 224 •...

  • Page 235: Removing And Installing Exterior Mirror

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.6.1 Removing – Remove mirror glass ⇒ page 223 – Remove mirror housing ⇒ page 224 – Remove trim ⇒ page 226 – Remove bolts -4- and remove assembly piece -1- downwards.
  • Page 236 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 2.7.2 Installing Installation is carried out in reverse order of removal. – Specified torque for exterior mirror bolts: 8 Nm • Test function before installing door trim. Rep. Gr.66 - Exterior equipment...

  • Page 237: Radiator Grille

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Radiator grille Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Assembly overview - radiator grille 1 - Radiator grille ❑ Material: ASA 2 - Retaining hook ❑...

  • Page 238: Removing And Installing Radiator Grille

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing radiator grille 3.3.1 Removing – Remove bolts -4-. – Release clips -arrows- on lock carrier using a small screw‐ driver. – Tilt radiator grille -1- backwards slightly and pull locking hooks -2- upwards out of bumper cover.

  • Page 239: Assembly Overview - Radiator Grille For Gti, Gti Special Models And Gt

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.3.2 Installing – With radiator grille-1- tilted forward slightly place locking hooks -2- in the bumper cover. – Clip radiator -1- to lock carrier and engage clips -arrows- in lock carrier.
  • Page 240 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 1 - Radiator grille ❑ Different appearance for Golf GT and Golf GTI ❑ Material: ASA 2 - Bolt ❑ Qty. 2 ❑ 2 Nm 3 - Decorative trim ❑ Only for Golf GTI ❑...

  • Page 241: Removing And Installing Radiator Grille For Gt, Gti Special Models And Gt

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing radiator grille for GT, GTI special models and GT Note The radiator grilles for the Golf GT and the Golf GTI differ only in their appearance. 3.5.1 Removing –...
  • Page 242 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.5.2 Installing – Insert lower edge of radiator grille horizontally into bumper cover -arrow c-. – Fold radiator grille upwards -arrow b-. – Guide radiator grille into guide hooks -5- from above -arrow c-.

  • Page 243: Radiator Grille For Gti, Gti Special Models, Gt And R32 - Number Plate Carrier

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Radiator grille for GTI, GTI special models, GT and R32 - number plate carrier 1 - Radiator grille ❑ With no securing holes. 2 - Number plate carrier ❑ For various countries ❑...

  • Page 244: Assembly Overview - Radiator Grille For R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - radiator grille for R32 1 - Radiator grille ❑ Material: ASA ❑ Removing: 2 - Left air intake grille ❑ Removing: ⇒ page 237 3 - Bolt ❑...

  • Page 245: Removing And Installing Radiator Grille For R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing radiator grille for R32 3.8.1 Removing – Remove bolts -4- and pull air grilles -3 and 6- in -direction of arrow a- and out of retaining clips in bumper cover.
  • Page 246 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 3.8.2 Installing – Place radiator grille -1- in bumper cover. – The side locking devices and locking hooks -7- must engage audibly. – Tighten bolts, specified torque for bolts -2- and -5-: 2 Nm and bolt -8-: 1 Nm.

  • Page 247: R32 Radiator Grille - Company Emblem

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 R32 radiator grille - company emblem 1 - VW emblem ❑ Removing: – Release locking lugs -arrow c- ❑ Installing: – Position company em‐ blem -arrow a- and turn in -direction of arrow b- 2 - R32 lettering ❑...

  • Page 248: Mouldings And Trims

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Mouldings and trims Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Hot air blower -V.A.G 1416- Rep. Gr.66 - Exterior equipment...

  • Page 249: Assembly Overview - Water Deflector

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - water deflector Note The right side is shown. The left side is similar. 1 - Water deflector 2 - Retaining strip 3 - Pop rivet ❑ Qty. 5...

  • Page 250: Removing And Installing Water Deflector

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing water deflector 4.3.1 Removing – Lever water deflector -1- out of retaining strip -2- starting at top. – Pull clip -4- out of retainer -5- in lower area of wing.
  • Page 251 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.3.2 Installing – Attach clip -4- in retainer -5-. – Press water deflector -1- into retaining strip -2- from bottom to top. 4. Mouldings and trims...

  • Page 252: Assembly Overview - Protective Side Strips

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - protective side strips Note Only the left side is shown. The procedure for the right side is similar. 1 - Front door protective side strip ❑ Material PP/EPDM ❑...

  • Page 253: Renewing Side Protective Mouldings

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Renewing side protective mouldings Note Installation is only described for the left side. The procedure for the right side is similar. ♦ Remove protective backing immediately before installation. Working temperature approx. 21 °C ♦...

  • Page 254: Removing And Installing Stone-Chip Protection Trim

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Only remove protective backing from side protective strips -1- and -2- immediately before fitting. • Bonding surfaces must be free of dust and grease. – Position protective side strips -1- and -2- on vehicle and press on using force.
  • Page 255 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.6.2 Installing Note The stone-chip protection trim securing screws are corrosion- ♦ resistant. No further secondary treatment is required. If a screw is overtightened, it is essential to replace it with a ♦...
  • Page 256 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note Dimension -a- is measured including wheel housing liner -2-. The other dimensions -b through i- are always ♦ measured from the centres of the holes. Dimension -k- can only be measured on 4-door vehicles.
  • Page 257 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • If all securing screw holes are pre-drilled. – Screw in self-tapping screws -2- with cordless drill/driver -VAS 5036- , using the highest speed, until the screw takes hold. Remove cordless drill/driver from head of screw immediately.

  • Page 258: Assembly Overview - Side Member Extension For Gti, Gti Special Models And R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Assembly overview - side member extension for GTI, GTI special models and R32 1 - Side member extension ❑ Removing ⇒ page 251 ❑ Installing ⇒ page 252 2 - Bolt ❑...

  • Page 259: Removing And Installing Side Member Extension For Gti, Gti Special Models And R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Removing and installing side member extension for GTI, GTI special models and R32 4.8.1 Removing – Remove bolts -2-. – Before removing, heat side member extension -1- in bonding surface area -4- with hot air blower -V.A.G 1416- .
  • Page 260 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.8.2 Installing Note Installation is only described for the left side. The procedure for the right side is similar. ♦ Remove protective backing immediately before installation. Working temperature approx. 21 °C ♦...

  • Page 261: Retaining Strip For Side Member Extension

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Position side member extension -1- from above -arrows- even‐ ly into retaining strip -3- and press side member extension into retaining strip until the two parts engage. – Now pull protective films -2- on side member extension -1- off upwards and backwards.
  • Page 262 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 4.9.2 Installing Note The securing screws for the retaining strip are corrosion-re‐ ♦ sistant. No further secondary treatment is required. If a screw is overtightened, it is essential to replace it with a ♦...
  • Page 263 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note Dimension -a- is measured including wheel housing liner -2-. The other dimensions -b through i- are always ♦ measured from the centres of the holes. Dimension -k- can only be measured in rear area on 4-door vehicles.
  • Page 264 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 • If all securing bolt holes are pre-drilled ⇒ page 254 – Screw in self-tapping screws -3- with cordless drill/driver -VAS 5036- , using the highest speed, until the screw takes hold.

  • Page 265: Roof Edge Spoiler

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Roof edge spoiler Tools Special tools and workshop equipment required ♦ Removal kit for flush bon‐ ded windows - V.A.G 1474 A- ♦ Suction lifter -V.A.G 1344- ♦ Cutting tool -V.A.G 1351- ♦...

  • Page 266: Assembly Overview - Roof Spoiler For Gti, Gti Special Models And R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Note Observe instructions for use on the information sheet provided by the manufacturer. Use double cartridge gun -VAS 5237- to apply two-component adhesives. Heat one-component window adhesive according to manufactur‐...

  • Page 267: Removing And Installing Roof Spoiler For Gti, Gti Special Models And R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 ❑ Installation instructions ⇒ page 264 Removing and installing roof spoiler for GTI, GTI special models and R32 5.4.1 Removing WARNING Clean all surrounding parts before beginning work and mask them with tape.
  • Page 268 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Repeat adhesive tape and adhesive bead separation on the other side. Note The middle hook is present only on vehicles from 02.05. – Push several wedges -3409- between rear lid -1- and roof spoiler -arrows a- until all hooks -2- are released.
  • Page 269 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 5.4.2 Installing Note Check all hooks for damage and renew the roof spoiler if necessary. • Retaining strip -6- installed ⇒ page 263 • Brake light in roof spoiler is installed ⇒ Electrical system; Rep.

  • Page 270: Retaining Strip

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – If roof spoilers are re-used, secure corners of roof spoiler to rear lid with commercially available adhesive tape. Retaining strip 5.5.1 Removing retaining strip • Roof spoiler is removed ⇒...

  • Page 271: Preparing Body Kit Component For Bonding

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 5.5.2 Installing retaining strip • Bonding areas -2- on retaining strip and rear lid have been primed. – Apply adhesive bead to retaining strip recess. – Align retaining strip -4- with original cut-out for brake light -3-.

  • Page 272: Installation Instructions

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 WARNING Activator must not have contact with paint or the paintwork will be damaged. Note If the body kit part has been repaired or partially renewed, the area concerned must be cleaned and primed again after painting.

  • Page 273: Cleaning Off Excess Adhesive Sealing Material

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 5.10 Cleaning off excess adhesive sealing material – Use of adhesive remover -D 002 000 10- as a cleaning solution is recommended. Observe the appropriate safety precautions when performing this work.

  • Page 274: Protective Backing

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Protective backing Attachment notes for protective backing Note Before removal, heat the scuff protection film with a hot air ♦ blower -V.A.G 1416- . Use only adhesive remover -D 002 000 10- to remove residual ♦...

  • Page 275: Renewing Scuff Protection Film

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Renewing scuff protection film Note Renewing scuff protection films is described only for the left side. The right side is similar. Removing – Removing inner seal for front door in area of side member ⇒...

  • Page 276: Lettering

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Lettering Tools Special tools and workshop equipment required ♦ Hot air blower -V.A.G 1416- Installation instructions for lettering and emblems Note Before removal, heat the lettering or the emblem with a hot air ♦...

  • Page 277: Rear Lettering Dimensions

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear lettering dimensions 1 - Dimension a = 50 mm ❑ From outer edge of rear lid to lettering 2 - Dimension b = 90 mm ❑ From lower edge of rear lid to lower edge of let‐...

  • Page 278: Rear Lettering Dimensions For Gti And R32

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear lettering dimensions for GTI and R32 1 - Dimension a = 50 mm ❑ From outer edge of rear lid to lettering 2 - Dimension b = 90 mm ❑...
  • Page 279 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 7.4.1 Rear lettering dimensions for GTI special models 1 - Dimension a = 50 mm ❑ From outer edge of rear lid to lettering 2 - Dimension b = 90 mm ❑...

  • Page 280: Rear Lettering Dimensions - Usa

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Rear lettering dimensions - USA 1 - Dimension a = 50 mm ❑ From outer edge of rear lid to lettering 2 - Dimension b = 90 mm ❑ From lower edge of rear lid to lower edge of let‐...

  • Page 281: Side Lettering Dimensions - Individual

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Side lettering dimensions - Individual 7.6.1 Dimensions of emblem, left wing 1 - Dimension a = 551 mm ❑ Transfer the -dimension a - from the underside of the wing to the wing.
  • Page 282 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 7.6.2 Dimensions of emblem, right wing 1 - Dimension a = 550 mm ❑ Transfer the -dimension a - from the underside of the wing to the wing. 2 - Dimension b = 30 mm ❑...
  • Page 283 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 7.6.3 Dimensions of R-line emblem Note The dimensions of the R-line emblem are described only for the left side. The right side is similar. ♦ The dimensions -b- and -c- indicate the inclination of the logo. The logo must be bonded parallel to the lower ♦...

  • Page 284: Vermin Repellent System

    Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 Vermin repellent system Volkswagen Individual optional equipment Assembly overview - vermin repellent system Note The items 2 to 5 are also installed on the passenger side. ♦ The system prevents access for vermin.
  • Page 285 Golf 2004 ➤ General body repairs, exterior - Edition 04.2008 – Unscrew bolts -1-. – Remove parts from vehicle. – Remove bolts -2- from protective part -1-. Note The protective parts may have a different appearance depending on engine fitted.

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