VW Golf Mk5 2004 General body repairs, exterior - Workshop Manual

1.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items......Page 9
1.2 Assembly overview - lock carrier, service position......Page 10
1.3.1 Moving to service position......Page 11
1.4.1 Removing......Page 12
1.4.2 Installing......Page 14
2.1 Tools......Page 15
2.3 Removing and installing wing......Page 16
2.3.1 Removing......Page 17
2.4.1 Removing......Page 18
2.4.2 Installing......Page 19
3.1 Tools......Page 20
3.2 Assembly overview - noise insulation......Page 21
4.1 Tools......Page 22
4.2 Assembly overview - underbody cladding......Page 23
5.2 Assembly overview - plenum chamber bulkhead......Page 24
1.1 Tools......Page 25
1.2 Assembly overview - bonnet......Page 26
1.3.2 Installing......Page 27
1.6 Removing and installing flap hinge......Page 28
1.6.2 Installing......Page 29
1.7.1 Removing......Page 30
1.7.2 Installing......Page 31
1.8 Assembly overview - bonnet latch and release components......Page 32
1.9.2 Installing......Page 33
1.11 Adjusting bonnet......Page 34
1.11.1 Adjusting bonnet lock......Page 35
1.12.2 Installing......Page 36
2.2 Assembly overview - rear lid......Page 37
2.3.2 Installing......Page 38
2.6 Removing and installing rear lid hinges......Page 39
2.6.1 Removing......Page 40
2.6.2 Installing......Page 41
2.8 Adjusting lid......Page 42
2.8.2 Adjusting adjustment buffer......Page 43
2.10 Removing and installing release element......Page 45
2.10.2 Installing......Page 46
2.12 Rear lid seal......Page 47
2.13.2 Installing......Page 48
3.2 Assembly overview - tank flap unit......Page 49
3.2.1 Removing tank flap unit......Page 50
3.2.2 Installing tank flap unit......Page 51
3.2.4 Installing actuator......Page 52
1.1 Tools......Page 53
1.3 Assembly overview - door assembly......Page 54
1.4 Assembly overview - door hinges......Page 56
1.5 Removing and installing door......Page 58
1.5.2 Installing......Page 59
1.6.1 Adjusting door gaps......Page 60
1.6.2 Adjusting door fittings for flushness......Page 62
1.7.1 Removing......Page 63
1.7.2 Installing......Page 65
1.8 Installing new outer panel for door......Page 66
1.9.1 Removing retaining rail......Page 70
1.10 Installation instructions for bonding in new door outer panel......Page 71
1.12 Cleaning off excess adhesive sealing material......Page 72
1.13 Assembly overview - door inner part......Page 73
1.14 Assembly overview - door handle and door lock......Page 74
1.15.2 Installing......Page 75
1.16.1 Removing......Page 76
1.16.2 Installing......Page 77
1.17 Removing and installing mounting plate......Page 78
1.17.1 Removing......Page 79
1.18 Removing and installing door lock......Page 80
1.18.2 Installing......Page 81
1.20 Door inner seal......Page 82
1.21.1 Removing......Page 83
1.21.2 Installing......Page 84
1.22.1 Removing......Page 85
1.22.2 Installing......Page 86
2.1 Location overview - central locking components......Page 88
2.2 Adapting keys with remote control......Page 89
2.3 Assembly overview - battery for folding key with remote control......Page 90
2.4.2 Installing......Page 91
1.1 Tools......Page 93
1.3 Assembly overview - door assembly......Page 94
1.4 Assembly overview - door hinges......Page 96
1.5 Removing and installing door......Page 97
1.5.2 Installing......Page 98
1.6.1 Adjusting door gaps......Page 99
1.6.2 Adjusting door fittings for flushness......Page 101
1.7.1 Removing......Page 102
1.7.2 Installing......Page 104
1.8 Installing new outer panel for door......Page 105
1.9.1 Removing retaining rail......Page 109
1.10 Installation instructions for bonding in new door outer panel......Page 110
1.12 Cleaning off excess adhesive sealing material......Page 111
1.13 Assembly overview - door inner part......Page 112
1.14 Assembly overview - door handle and door lock......Page 113
1.16 Removing and installing door handle......Page 114
1.16.2 Installing......Page 115
1.17 Removing bearing bracket......Page 116
1.17.1 Removing......Page 117
1.18 Removing and installing door lock......Page 118
1.19 Assembly overview - side impact protection......Page 119
1.20 Door inner seals......Page 120
1.21.1 Removing......Page 121
1.22 Removing and installing door outer seal......Page 122
1.22.1 Removing......Page 123
1.22.2 Installing......Page 124
1.1.1 Required special tools, workshop equipment, test and measuring devices and auxiliary items......Page 126
1.2 Function......Page 127
1.3 Assembly overview - sliding/tilting sunroof with glass panel......Page 128
1.4.1 Removing......Page 130
1.5 Removing glass panel of sliding/tilting sunroof......Page 131
1.7 Adjusting height of glass panel of sliding/tilting sunroof......Page 132
1.8 Adjusting panel seal......Page 133
1.10.1 Removing......Page 134
1.11.1 Removing......Page 135
1.12.1 Removing......Page 136
1.13 Adjusting drive for sliding/tilting sunroof glass panel (0 position)......Page 137
1.16 Adjusting parallel running......Page 138
1.17 Assembly overview - carrier unit......Page 139
1.18.1 Removing......Page 140
1.18.2 Installing......Page 141
1.20.1 Removing......Page 142
1.21.1 Removing......Page 143
1.22 Cleaning water drain hoses......Page 144
1.22.1 Front water drain hoses......Page 145
1.22.2 Rear water drain hoses......Page 146
1.2 Repairing bumper cover......Page 147
1.4 Removing and installing front bumper cover......Page 148
1.4.2 Installing......Page 149
1.5 Front bumper attachments......Page 150
1.6 Front bumper substructure......Page 151
1.7 Assembly overview - bumper carrier......Page 152
1.8 Assembly overview - number plate carrier......Page 153
2.3 Assembly overview - bumper cover for GTI, GT......Page 154
2.4 Removing and installing front bumper cover for GT, GTI......Page 155
2.4.2 Installing......Page 156
2.5 Front bumper attachments for GT, GTI......Page 157
2.7 Removing and installing front bumper cover for R32......Page 159
2.7.2 Installing......Page 160
2.8 Front bumper attachments for R32......Page 161
2.10 Removing and installing front bumper cover for GTI special models......Page 162
2.10.2 Installing......Page 163
2.11 Front bumper attachments for GTI special models......Page 164
2.12 Front bumper substructure......Page 165
2.13 Assembly overview - bumper carrier......Page 166
3.2 Repairing bumper cover......Page 167
3.4 Removing and installing bumper cover......Page 168
3.4.1 Removing......Page 169
3.5 Rear bumper attachments......Page 170
3.6 Rear bumper substructure......Page 171
3.8 Assembly overview - towing bracket......Page 172
4.2 Repairing bumper cover......Page 174
4.4 Removing and installing bumper cover for R32......Page 175
4.4.2 Installing......Page 176
4.5 Rear bumper attachments for R32......Page 177
4.7 Removing and installing rear bumper cover for GTI special models......Page 178
4.7.2 Installing......Page 179
4.8 Rear bumper attachments for GTI special models......Page 180
4.9 Rear bumper substructure......Page 181
4.10 Assembly overview - bumper carrier......Page 182
1.1 Tools......Page 183
1.3 Repairing windscreen......Page 185
1.4 Assembly overview - windscreen......Page 186
1.5 Assembly overview - plenum chamber cover......Page 187
1.5.1 Removing plenum chamber cover......Page 188
1.5.2 Installing plenum chamber cover......Page 189
1.7 Installing windscreen......Page 190
1.9 Removing undamaged rear window......Page 191
1.10 Removing broken rear window......Page 192
1.11 Installing rear window......Page 193
1.13 Removing undamaged rear side window......Page 194
1.15 Installing rear side window......Page 195
1.17 Preparing new window without precoating for glazing......Page 196
1.18 Preparing new window with precoating for glazing......Page 197
1.19 Preparing body flange for glazing......Page 198
1.21 Minimum curing period......Page 199
1.23 Cleaning off excess adhesive sealing material......Page 200
2.1 Tools......Page 201
2.2 Assembly overview - front door window......Page 202
2.3.1 Removing......Page 203
2.3.2 Installing......Page 204
2.4 Adjusting door window......Page 205
2.5 Assembly overview - window regulator motor......Page 206
2.6.1 Removing......Page 207
2.6.2 Installing......Page 208
2.8 Removing and installing window guide......Page 209
2.8.2 Installing......Page 210
2.10 Removing and installing window regulator......Page 211
2.10.2 Installing......Page 212
3.1 Tools......Page 213
3.3 Removing and installing door window......Page 214
3.3.1 Removing......Page 215
3.3.2 Installing......Page 216
3.5.1 Removing......Page 217
3.5.2 Installing......Page 219
3.7 Removing and installing window regulator motor......Page 220
3.7.1 Removing......Page 221
3.7.2 Installing......Page 222
3.9 Removing and installing window regulator......Page 223
3.9.2 Installing......Page 224
1.1 Tools......Page 225
1.3 Removing and installing front wheel housing liner......Page 226
1.3.2 Installing......Page 227
1.5 Removing and installing rear wheel housing liner......Page 228
1.5.2 Installing......Page 229
2.1 Tools......Page 230
2.3 Removing and installing mirror glass......Page 231
2.4 Removing and installing mirror housing......Page 232
2.4.1 Removing......Page 233
2.6 Removing and installing side turn signals......Page 234
2.7.1 Removing......Page 235
2.7.2 Installing......Page 236
3.2 Assembly overview - radiator grille......Page 237
3.3.1 Removing......Page 238
3.4 Assembly overview - radiator grille for GTI, GTI special models and GT......Page 239
3.5.1 Removing......Page 241
3.5.2 Installing......Page 242
3.6 Radiator grille for GTI, GTI special models, GT and R32 - number plate carrier......Page 243
3.7 Assembly overview - radiator grille for R32......Page 244
3.8.1 Removing......Page 245
3.8.2 Installing......Page 246
3.9 R32 radiator grille - company emblem......Page 247
4.1 Tools......Page 248
4.2 Assembly overview - water deflector......Page 249
4.3.1 Removing......Page 250
4.3.2 Installing......Page 251
4.4 Assembly overview - protective side strips......Page 252
4.5 Renewing side protective mouldings......Page 253
4.6.1 Removing......Page 254
4.6.2 Installing......Page 255
4.7 Assembly overview - side member extension for GTI, GTI special models and R32......Page 258
4.8.1 Removing......Page 259
4.8.2 Installing......Page 260
4.9.1 Removing......Page 261
4.9.2 Installing......Page 262
5.2 Materials......Page 265
5.3 Assembly overview - roof spoiler for GTI, GTI special models and R32......Page 266
5.4.1 Removing......Page 267
5.4.2 Installing......Page 269
5.5.1 Removing retaining strip......Page 270
5.6 Preparing body kit component for bonding......Page 271
5.9 Touching up paint damage......Page 272
5.10 Cleaning off excess adhesive sealing material......Page 273
6.1 Attachment notes for protective backing......Page 274
6.2 Renewing scuff protection film......Page 275
7.2 Installation instructions for lettering and emblems......Page 276
7.3 Rear lettering dimensions......Page 277
7.4 Rear lettering dimensions for GTI and R32......Page 278
7.4.1 Rear lettering dimensions for GTI special models......Page 279
7.5 Rear lettering dimensions - USA......Page 280
7.6.1 Dimensions of emblem, left wing......Page 281
7.6.2 Dimensions of emblem, right wing......Page 282
7.6.3 Dimensions of R-line emblem......Page 283
8.1.1 Removing......Page 284
8.1.2 Installing......Page 285