Rear lid. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

Transcription

1 Rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Rear lid

2 Tools vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Tools Special tools and workshop equipment required Torque wrench -V.A.G Torque wrench -V.A.G Socket -T10010-

3 Tools vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2

4 Assembly overview - rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview - rear lid 1 - Rear lid 2 - Lid lock Removing and installing Chapter Adjusting Chapter Removing and installing Chapter 3 - Handle trim 4 - Damper Removing and installing Chapter 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 8 - Hinge Adjusting Chapter Removing and installing Chapter

5 Removing and installing rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing rear lid

6 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

7 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Rear lid -1- installation is performed in the reverse order of removal. Tighten bolts -2- to 20 Nm. Note Carry out corrosion protection measures on lid hinge and securing bolts after assembly work.

8 Removing gas-filled strut vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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 gasfilled strut -1-, slide spring clip -2- back immediately. WARNING Proceed 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. Gasfilled strut springs out of mounting and causes damage or injury to operator. Specified torque for ball-head pins -3- and Nm. Releasing gas from gas-filled strut -1- Chapter.

9 Removing and installing handle trim vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing handle trim

10 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

11 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Handle trim -1- installation is carried out in reverse order of removal. Tighten hexagon nuts -3- to 4.5 Nm.

12 Removing and installing rear lid hinges vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing rear lid hinges Note Removal and installation is described for the right hinge only. Apply the same instructions for the left-hand side as appropriate.

13 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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. Note 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.

14 Installing Installing Note 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 long. 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. Note Carry out corrosion protection measures on lid hinge and securing bolts after assembly and adjustment work. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

15 Adjusting rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Adjusting rear lid The 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.

16 Adjusting rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Adjusting rear lid The 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.

17 Basic adjustment of rear lid Page 1 of 2 Basic adjustment of rear lid Note 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). Note 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. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

18 Basic adjustment of rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 Tighten hexagon nuts -1- to 20 Nm. Adjusting guide pins Chapter.

19 Adjusting striker pin Adjusting striker pin Note 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. 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 oversize 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. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

20 Adjusting striker pin for power latching system Adjusting striker pin for power latching system Note 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. 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. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

21 Adjusting guide wedge and guide pin vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Adjusting guide wedge and guide pin

22 Assembly overview vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview 1 - Bolt Qty. 2 Specified torque 8 Nm 2 - Guide pin 3 - Bolt Left and right Qty. 2 Specified torque 8 Nm 4 - Guide wedge Left and right

23 Adjusting guide pins vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

24 Adjusting stop buffers Page 1 of 2 Adjusting stop buffers Note 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. 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 - vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

25 Adjusting stop buffers vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 a = 25 mm-. Check setting.

26 Assembly overview - rear lid latch and release components vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview - rear lid latch and release components

27 Assembly overview - lock carrier vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview - lock carrier 1 - Carrier for locking mechanism With central locking and interior release mechanism Removing and installing Chapter 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 installing Chapter 7 - Connector 8 - Child-proof control 9 - Trim 10 - Bolt For vehicles with moulded trim Removing and installing Chapter For vehicles with moulded trim General body repairs, interior; Rep. Gr.70. 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 Operating rod for door interior opening mechanism 14 - Rear lid Removing and installing Chapter Adjusting Chapter

28 Assembly overview - lock cylinder housing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview - lock cylinder housing For vehicles with no inner operating mechanism 1 - Handle 2 - Bolt Qty Nm 3 - Bonnet lock 4 - Bolt Removing Chapter Installing Chapter Qty. 3 Specified torque 4.5 Nm 5 - Pull rod 6 - Lock cylinder housing Removing and installing Chapter 7 - Retaining clip 8 - Pull rod 9 - Central locking control motor Removing: Separate connector on control motor Unscrew control motor using socket driver - T and unhook out of rear lid. Installing: Install in reverse order of removal.

29 Removing and installing rear lid lock vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing rear lid lock

30 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

31 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Rear lid lock -2- installation is carried out in reverse order of removal. Tighten bolts -3- to 20 Nm. Note 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.

32 Removing and installing childproof lock operating device vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing childproof lock operating device

33 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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-.

34 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

35 Removing and installing carrier for rear lid locking vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing carrier for rear lid locking Note The removal and installation procedures may have to be revised slightly depending on model.

36 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 4 Removing Remove rear lid trim General body repairs, interior; Rep. Gr.70 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.

37 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 4 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. Note 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-.

38 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 3 of 4 Press centre locking tab on latch carrier -arrow a - back from inner part of lid.

39 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 4 of 4 Remove latch carrier -1-, together with striker plate, as a single unit from rear lid in -direction of arrow-.

40 Installing Installing Install retaining clip for lock cylinder - arrow- on exterior handle. Further installation is performed in the reverse order of removal. Note 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. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

41 Removing and installing lock cylinder vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing lock cylinder

42 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing Remove rear lid trim General body repairs, interior; Rep. Gr.70 Remove exterior handle Chapter Press lock cylinder -2- in -direction of arrow- out of latch carrier -1-. Note 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.

43 Installing 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. Note 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. Before installing rear lid trim and closing rear lid, check function of the lid locking and release components. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

44 Removing and installing lock cylinder housing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing lock cylinder housing For 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 Linkage clip For rear lid lock Item 12 - Linkage clip For control motor Item

45 Interior opening mechanism vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Interior opening mechanism

46 Assembly overview vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview 1 - 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

47 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

48 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Installation is the reverse of removal. Note Before installing rear lid trim and closing rear lid, check function of the lid locking and release components.

49 Removing and installing rear lid seal Removing and installing rear lid seal Note 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. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

50 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

51 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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

52 Rear lid trims vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Rear lid trims

53 Tools vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Tools Special tools and workshop equipment required Release lever -T Pop-rivet nut pliers -V.A.G 1765B-

54 Removing and installing window frame trim for rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing window frame trim for rear lid

55 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing Switch off ignition. Pull window frame trim -2- off window frame, starting at sides.

56 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Note Before installing, check fasteners -1- for damage and renew if necessary. Installation is carried out in reverse order of removal.

57 Removing and installing lower rear lid trim vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing lower rear lid trim

58 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Removing All vehicles Remove rear lid window frame trim Chapter. Only vehicles with additional inner lock in rear lid Note 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 (Ñ 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. Caution Damage to rear lid trim. Trim must be renewed if care is not exercised.

59 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 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 -T

60 Installing Installing Note 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. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

61 Assembly overview - hardboard trim for lower area of rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview - hardboard trim for lower area of rear lid 1 - 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 4 - Clip Removing and installing Chapter Qty Bolt Qty. 2 Specified torque: 3.5 Nm 6 - Pull loop 7 - Cover for wiper motor 8 - Grommet Qty. 2

62 Removing and installing lower hardboard trim for rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing lower hardboard trim for rear lid

63 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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-.

64 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Note Before installing, check securing clips for damage and renew if necessary. Installation is carried out in reverse order of removal.

65 Rear window wiper system (vehicles with rear lid) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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 to perform fault finding. Caution To disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to Chapter.

66 Rear window wiper motorv12 vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Rear window wiper motor -V12-

67 Assembly overview Assembly overview Caution Ensure rubber seals -1- for wiper shaft are seated correctly in door panel. Apply lubricant: polyethyleneglycol to wiper shaft Rubber seal (Use seal with marking pointing upwards with a deviation of -a- = ±10 ) 2 - Rear lid 3 - Securing nuts 4 - Hose connection for windscreen washer system 5 - Rear window wiper motor -V Wiper shaft (use polyethyleneglycol as lubricant during installation) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

68 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Removing Special tools and workshop equipment required Torque wrench (5-50 Nm) -V.A.G 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

69 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 Pull connector -1- off wiper motor. Pull off hose connection piece -2- for window washer system. Remove hexagon nuts -3-. Remove wiper motor -4-.

70 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Carry out installation in the reverse sequence, noting the following: Caution Ensure rubber seal for wiper shaft is seated correctly in door panel Insert rubber seal Anchor. Caution Apply 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.

71 Removing and installing windscreen wiper blades vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Removing and installing windscreen wiper blades Removing 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. Note Avoid bending the windscreen wiper arm and blade. Avoid windscreen wiper arm springing back unintentionally and damaging the glass. Pull windscreen wiper blade -2-90Ö 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

72 Removing and installing windscreen wiper blades vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 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.

73 Adjusting rear window wiper park position vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Adjusting rear window wiper park position Special tools and workshop equipment required Torque wrench (5-50 Nm) -V.A.G 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.

74 Rear window washer system (vehicles with rear lid) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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 to perform fault finding. Caution To disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to Chapter.

75 Assembly overview - rear window washer system (vehicles with rear lid) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 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 Removing and installing Chapter Adjusting Chapter 2 - Connection piece Connection to rear window spray jet Overview of hose couplings for washer fluid lines Chapter 3 - Connection piece 4 - Hose Separating point between roof wiring harness and rear lid wiring harness Overview of hose couplings for washer fluid lines Chapter 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

76 Assembly overview - rear window washer system (vehicles with rear lid) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 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

77 Renewing washer spray jet vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Renewing washer spray jet

78 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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-.

79 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Install in reverse order of removal.

80 Adjusting washer spray jet vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Adjusting washer spray jet Adjusting washer spray jet Booklet19.1

81 Windscreen wash/wipe system and headlight washer system: Check function and setti... Page 1 of 5 Windscreen wash/wipe system and headlight washer system: Check function and settings Check anti-freeze concentration of Windscreen Clear with anti-freeze -G , 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 necessary Checking anti-freeze concentration Special tools and workshop equipment required Refractometer -T 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 -T (refer to operating instructions). The scale -1- of the refractometer is calibrated for Genuine Volkswagen Windscreen Clear with anti-freeze -G 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 Mixture ratio Frost protection to Windscreen Clear with anti-freeze Water vw-wi://igg/n.en-gb.k wi:: xml?xsl=3

82 Windscreen wash/wipe system and headlight washer system: Check function and setti... Page 2 of 5 G /-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 all-year-round when replenishing windscreen wash/wipe system. Note All vehicles having fan-type spray jets, the reservoir must be filled with Windscreen Clear with anti-freeze -G , 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 antifreeze -G ensures that the fan-type spray jets remain fully functional also at low temperatures. Genuine Volkswagen Windscreen Clear with anti-freeze -G protects the spray jets, fluid reservoir and connecting hoses from freezing. Use Genuine Volkswagen Windscreen Clear with anti-freeze - G 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 necessary Special tools and workshop equipment required Setting device -T equipped with needle 3125/5 A Note 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: vw-wi://igg/n.en-gb.k wi:: xml?xsl=3

83 Windscreen wash/wipe system and headlight washer system: Check function and setti... vw-wi://igg/n.en-gb.k wi:: xml?xsl=3 Page 3 of 5 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 - T so that the water jet sprays onto the upper third of rear window. Rear window spray jet setting / rear wing doors:

84 Windscreen wash/wipe system and headlight washer system: Check function and setti... vw-wi://igg/n.en-gb.k wi:: xml?xsl=3 Page 4 of 5 Adjust spray jet using adjusting tool - T so that the water jets spray onto rear window at positions shown. Note 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 necessary Special tools and workshop equipment required Adjusting tool -T The jet adjustment dimensions are for the lefthand 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.

85 Windscreen wash/wipe system and headlight washer system: Check function and setti... Page 5 of 5 Perform the following procedure: Align the spray direction of respective jet using adjusting tool -T at points illustrated. Note 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 Note If stream of water is uneven or cannot be adjusted to specified dimensions, renew washer jet (repair measure). vw-wi://igg/n.en-gb.k wi:: xml?xsl=3

86 High level brake light bulbm25 vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 High level brake light bulb -M25-

87 Rear lid vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Rear lid

88 Removing and installing high-level brake lightm25 vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

89 Renewing bulbs/ light emitting diodes (LED) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Renewing bulbs/ light emitting diodes (LED) Note The high-level brake light -M25- must be replaced as a complete unit in the event of repairs.

90 Roof trims vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Roof trims

91 Tools vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Tools Special tools and workshop equipment required Release lever -T Torque wrench -V.A.G 1783-

92 Removing and installing roof frame trim vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing roof frame trim

93 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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-.

94 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Note 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-. Installation is carried out in reverse order of removal.

95 Assembly overview - roof frame trim vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Assembly overview - roof frame trim Note 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 3 - Channel With right and left sliding door. 4 - Securing clip 5 - Clip At front and rear only. For roof frame trim without sliding door. Qty Clip For roof frame trim with sliding door. Qty. 5

96 Assembly overview - moulded headlining (Multivan) vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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 Clip holder

97 Removing and installing moulded headlining for passenger compartment vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing moulded headlining for passenger compartment Note Removal and installation is described for the Multivan. Follow same instructions for the Transporter as appropriate.

98 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

99 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 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.

100 Removing and installing moulded headlining in area of front seats vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Removing and installing moulded headlining in area of front seats Note Removal and installation is described for the Multivan. Follow same instructions for the Transporter as appropriate.

101 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Removing Only 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.

102 Removing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 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.

103 Installing vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Installing Installation is carried out in reverse order of removal.