VOLKSWAGEN GOLF 2004 (03) PDF Document

WARNING

Pyrotechnic components always contain a propellant that generates a gas during combustion. On some versions, a separate compressed gas reservoir is available to generate the gas.

This compressed gas is stored under high pressure in a compressed gas tank.

Ignition of the pyrotechnic components is by means of an electric/mechanical igniter.

Testing, removing, installing and repair work may only be performed by qualified personnel.

For airbag units, there are no exchange intervals.

Under no circumstances should checks be carried out with a test lamp, voltmeter or ohmmeter.

Pyrotechnic components may only be checked in installed state and with vehicle diagnosis, testing and information systems approved by the manufacturer.

When working on pyrotechnic components and airbag control unit -J234-, the battery earth strap must be disconnected with the ignition switched on. Then cover negative terminal.

A waiting time of 10 seconds is necessary after disconnecting the battery.

The battery must be connected with the ignition SWITCHED ON. When doing this, there should be no-one inside the vehicle. Exception: Vehicles with battery inside passenger compartment. In this case do not stay anywhere near the effective range of the airbags and seat belts.

Wash hands after coming into contact with triggered pyrotechnic components of restraint system.

Pyrotechnic components must not be opened or repaired; always use new parts (risk of injury).

Pyrotechnic components that have been dropped onto a hard surface or show signs of damage must not be installed in a vehicle.

Before handling pyrotechnic components of the restraint system, for example before separating an electrical connection, the mechanic must electrostatically discharge him/herself. Electrostatic discharge is achieved by touching earthed metallic parts, such as the door striker plate.

Pyrotechnic components must be installed immediately after they have been removed from their packaging.

If work is interrupted, the pyrotechnic component must be stored back in its packaging.

Leaving the pyrotechnic component unattended is prohibited.

Pyrotechnic components must not come into contact with grease, cleaning solution or similar.

Pyrotechnic components must not be subjected to temperatures above 100 °C even for short periods.

WARNING

Never point open end of belt tensioner at another person.

Belt tensioner units must be handled with extreme caution during removal and installation. If handled incorrectly, there is a high risk of injury and damage in relation to the belt tensioner units.

When connecting the belt tensioner unit, all mechanical parts (including those of the 3-point seat belt) must be properly attached. If connection of the belt tensioner unit is hindered due to tight conditions, the belt strap must be rolled up completely before connecting. In this case there is no heightened risk of safety as long as the additional safety instructions are heeded. Essentially this is aimed at battery disconnection and electrostatic discharge of the fitter prior to connection of the belt tensioner unit.

Depending on the crash intensity, it is possible that the belt tensioner was triggered but the belt force limiter did NOT ignite. These parts are to be treated as unignited components!

WARNING

Storage must comply with the relevant national legislation.

Transportation is subject to national and international regulations that govern packaging, marking, labelling and freight documentation in detail.

Untriggered pyrotechnic components must be disposed of correctly in the original packaging in accordance with national legislation. Contact your importer if in any doubt.

Only completely ignited pyrotechnic components may be disposed of through the commercial waste system.

1.3.1 Removing

If vehicle is equipped with a rain sensor, switch off ignition.

Using removal wedge -3409- , release fastener -1- of right cover cap -2-.

Release left -3- and right cover caps -2- from mirror base.

Separate connector -4-.

Slide interior mirror along windscreen and then downwards out of mounting.

1.3.2 Installing

Install in reverse order of removal.

1.4.1 Preparing windscreen

All adhesive and primer residue must be removed from the ceramic pre-coating.

Clean adhesive surface with cleaning solution D 009 401 04.

Adhere to flash-off period of at least 10 minutes.

Apply glass/paint primer D 009 200 02.

Flash-off period up to bonding: minimum of 10 minutes to maximum of 1 hour.

1.4.2 Preparing detached or new mirror base

Mechanically remove adhesive remains (applies only for a mirror base which has become detached).

Prepare adhesive surface by sanding down with wet fine emery paper (800-1200 grade) until water does not run off surface to be bonded.

Then clean with cleaning solution D 009 401 04.

1.4.3 Bonding mirror base

Apply 2K polyurethane adhesive D 180 KD2 A1 directly to prepared and cleaned mirror base bonding surface.

Adhesive bead diameter: Approx. 2.5…3 mm.

Press mirror base into position on prepared windscreen immediately after applying adhesive to base.

Align mirror base in position on ceramic pre-coat surface and secure with adhesive tape.

1.4.4 Cleaning and removing excessive adhesive

Carefully remove adhesive tape 30 – 60 minutes after attaching mirror base.

Carefully remove the excessive but still soft adhesive with aid of a spatula.

Then remove the excessive adhesive completely using a cloth or primer applicator soaked in cleaning solution.

1.4.5 Installing rain sensor and mirror

Mirror can be fitted 2.5 hours after attaching mirror base.

1.5.1 Removing

Turn interior mirror -1- anti-clockwise through 90° -arrow- and release it from adhesive plate -2-.

1.5.2 Installing

Install in reverse order of removal.

1.6.1 Materials

Glass-metal adhesive kit “D 000 703 A1”

1.6.2 Tools

1 – Glass scraper (commercially available)

2 – Blade (commercially available)

Remove retaining plate from mirror base.

Remove PUR adhesive from mirror base using a wire brush.

Grind off the three spacer protrusions on bonding surface. To do this, use sandpaper (360/400 grain) laid on flat surface.

Keep sanded surface clean and free of grease.

Scrape down PUR adhesive material and primer down to ceramic layer on windscreen using glass scraper.

Clean bonding area with adhesive remover D 002 000 10 or cleaning solution D 009 401 04.

Caution

Do not damage ceramic coating. Scratches will remain permanently visible.

Cut nylon mesh fabric exactly to size of mirror base.

Note

Wear hand protection (rubber gloves).

Apply adhesive evenly and smoothly to base of mirror.

Fit nylon mesh fabric onto base of mirror.

Apply further adhesive to nylon mesh fabric by dabbing with tube.

After adhesive has been applied to nylon mesh fabric, base of mirror must be pressed onto windscreen within 30 seconds.

Press base of mirror firmly (do not use force) against windscreen for 15 seconds.

Remove excess adhesive with a cloth.

Note

Interior mirror can be installed after 15 minutes.

2.2.1 Removing

Switch off ignition.

Vehicles with automatic gearbox

Release selector lever boot from cover (refer to Rep. Gr. 37).

Vehicles with manual or direct shift gearbox

Release selector lever boot from cover (refer to Rep. Gr. 34).

All vehicles

Remove handbrake lever trim (refer to Rep. Gr. 46).

Remove the two trim lining mats -1- from the extension -3-.

Remove the three bolts -2- (1.5 Nm).

Release extension from mountings.

Pull extension forwards through opening for handbrake lever.

Release selector insulation -1- from centre console.

Remove the two bolts -2- (1.5 Nm).

Release storage compartments -3- from centre console and disconnect wiring harness (dependent on vehicle equipment).

Note

An ashtray may be installed instead of a storage compartment -3-, but the removal is identical.

Using a small screwdriver, unclip cover -1- from trim.

Remove bolt -2- (1.5 Nm).

Pull left footwell trim -3- out of mountings.

Note

Removal of right footwell trim is identical.

Unclip both side trims -4- from centre console by releasing fasteners with a removal wedge -3409- .

Remove the two bolts respectively -1- and -2- (1.5 Nm).

Remove the two bolts respectively -3- and -4- (1.5 Nm).

Remove bolt -5- (1.5 Nm).

Note

During installation, bolts must be installed in the sequence -1-, -2-, -3-, -4- and -5-.

Remove centre console from vehicle.

2.2.2 Installing

Install in reverse order of removal.

Switch off ignition.

Remove centre console (refer to page 15).

Remove both nuts -1- (8 Nm) and remove mounting bracket -2-.

Vehicles with automatic gearbox

Release selector lever boot from cover (refer to Rep. Gr. 37).

Vehicles with manual or dual clutch gearbox

Release selector lever boot from cover (refer to Rep. Gr. 34).

Removing storage compartment / ashtray unit (Golf 2004) (refer to page 47)

Unclip cover -1- from trim using a small screwdriver.

Remove bolt -2- (1.5 Nm).

Pull left footwell trim -3- out of mountings.

Detach right footwell trim, removal is identical.

It is not necessary to remove trim -4- on both sides.

Remove two bolts each -3- and -4- (1.5 Nm).

To remove securing bracket of centre console, it is not necessary to remove bolts -1-, -2- and -5-.

Switch off ignition.

All vehicles

Open cup holder -1- and remove the two bolts -2- (1.5 Nm).

Pull cup holder out of centre console.

Part renewal should only be carried out if repair is impossible, because e.g. components are severely deformed, broken, broken off or otherwise damaged and the flawless function of the cup holder is therefore no longer guaranteed.

Remove cup holder in centre console, Highline (refer to page 43).

Loosen cover -1- from cup holder -arrow-.

Check all four attachments -1- of cup holder for damage.

If an attachment -2- is severely deformed, the cup holder must be renewed.

Note

The cup holder must also be renewed if other components are damaged which normally ensure that the cup holder can function as designed.

Place lower cover -1- over outer mounting pins -2- and -3- in cup holder.

Position mounting pin -4- in front of mounting -5-.

Place upper part -6- over pin -7- and mounting pins -8- in cup holder.

The mounting -9- is placed in front of pin -10-.

Close cup holder; mountings -1- and -3- engage with corresponding pins -2- and -4-.

Open cup holder and insert cover.

2.10.1 Removing

Switch off ignition.

Vehicles with automatic gearbox

Release selector lever boot from cover (refer to Rep. Gr. 37).

Vehicles with manual or direct shift gearbox

Release selector lever boot from cover (refer to Rep. Gr. 34).

Remove the two bolts -1- (1.5 Nm).

Release storage compartments -2- from centre console and disconnect wiring harness (dependent on vehicle equipment).

Note

An ashtray may be installed instead of a storage compartment, but the removal is identical.

2.10.2 Installing

Install in reverse order of removal.

2.12.1 Removing

Remove lining mat -1- from storage compartment.

Remove the two bolts -2- (1.5 Nm).

Remove storage compartment -3- from vent -4-.

Vehicles with Climatronic

The positions -5-, -6-, -7-, -8- and -9- are exclusively for vehicles with Climatronic.

Remove dash panel centre vents (vehicles with Climatronic) (refer to page 50).

Note

Vehicles with no Climatronic, two templates -1- have already been removed at this point.

Insert two wedges -3409- into lower joint of vent -arrows- and press vent upwards out of mounting in dash panel.

2.12.2 Installing

Install in reverse order of removal.

Operate the respective locking devices and separate the wiring harnesses for hazard warning lights switch and front passenger airbag warning lamp.

2.13.2 Installing

Install in reverse order of removal.

2.18.1 Removing

Remove dash panel centre vent.

Vehicles with no Climatronic (Golf 2004) (refer to page 48)

Vehicles with Climatronic (Golf 2004) (refer to page 50)

Remove the two bolts -1- (1.5 Nm).

Using removal wedge -3409- , prise trim out of fasteners in dash panel (insert wedge close to fastener).

2.18.2 Installing

Install in reverse order of removal.

Glass-metal adhesive kit “D 000 703 A1”

Assembly overview

1 – Bolt (20 Nm)

2 – Bolt (40 Nm)

3 – Washer

4 – Anchor rail

5 – Bolt (40 Nm)

6 – Belt inertia reel, B-pillar

7 – Wiring harness

8 – Bolts (Qty. 2, 4.5 Nm)

9 – Belt guide

10 – Bolt (40 Nm)

11 – Belt guide fitting

12 – Belt buckle (Removing refer to page 98)

1.4.2 Removing

Note

Removal and installation are described for the left vehicle side. Follow same instructions for the right side as appropriate.

Disconnect vehicle battery (refer to Rep. Gr. 27).

Remove B-pillar upper trim (refer to page 228).

Remove bench seat (refer to page 304).

Remove backrest (refer to page 305).

Remove sill panel moulding (2-door) (refer to page 81).

Remove side panel trim (refer to page 233).

Remove bolt -1- (20 Nm).

Unscrew bolt -2- (40 Nm) and remove washer -3-.

Pull guide bar -4- through loop in belt strap.

Remove bolt -5- (40 Nm) and remove belt inertia reel -6- from B-pillar.

WARNING

Electrostatic discharges may result in unintentional triggering of belt tensioner. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting the igniter and earth wires. This can be done by briefly touching the body or striker plate of the door.

Disconnect connector -7-.

Remove bolts -8- (4.5 Nm) and remove belt guide -9-.

Remove bolt -10- (40 Nm) and remove belt guide fitting -11- from belt height adjuster.

Install in reverse order of removal.

Reconnect vehicle battery (refer to Rep. Gr. 27).

1 – Bolt (40 Nm)

2 – Belt end anchor

3 – Bolt (40 Nm)

4 – Belt inertia reel, B-pillar

5 – Wiring harness

6 – Bolts (Qty. 2, 4.5 Nm)

7 – Belt guide

8 – Bolt (40 Nm)

9 – Belt guide fitting

10 – Belt buckle (Removing refer to page 100)

1.5.2 Removing

Note

Removal and installation are described for the left vehicle side. Follow same instructions for the right side as appropriate.

Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27; Disconnecting and reconnecting battery).

Remove B-pillar upper trim (refer to page 228).

Remove B-pillar lower trim (refer to page 230).

Remove bolt -1- (40 Nm) and remove belt end anchor -2- from body.

Caution

Bolt -1- may be microencapsulated. For this reason, the bolt has to be heated with a hot air blower before it can be loosened. The neighbouring seat belt must be protected against the heat with a damp cloth when doing this.

Note

If the bolt is microencapsulated, it must be renewed if loosened.

Before a new bolt is installed, the thread of the nut must be cleaned and recut as necessary.

Remove bolt -3- (40 Nm) and remove belt inertia reel -4- from B-pillar.

WARNING

Electrostatic discharges may result in unintentional triggering of belt tensioner. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting the igniter and earth wires. This can be done by briefly touching the body or striker plate of the door.

Disconnect wiring harness -5-.

Remove bolts -6- (2 Nm) and remove belt guide -7-.

Remove bolt -8- (40 Nm) and remove belt guide fitting -9- from belt height adjuster.

Install in reverse order of removal.

Reconnect vehicle battery (refer to Rep. Gr. 27).

1.6.1 Removing

Remove B-pillar upper trim (refer to page 228).

Note

There is no need to remove the belt end anchor or anchor rail from front seat belt.

Remove bolt -1- (40 Nm) and remove belt guide fitting -2- from belt height adjuster.

Remove bolt -3- (20 Nm) and remove belt height adjuster -4- from mountings in support bracket.

1.6.2 Installing

Install in reverse order of removal.

1.7.1 Removing

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Move seat to forwardmost position.

Disconnect wiring harness -1- from seat frame, if part of original equipment.

Remove bolt -2- (20 Nm).

Note

The bolt is microencapsulated and must be renewed each time it is loosened.

Before a new bolt is installed, the thread of the corresponding nut must be cleaned.

Turn belt buckle 90° clockwise -arrow A-.

Swing belt buckle outwards -arrow B-.

Pull belt buckle out of mounting in seat rail -arrow C-.

1.7.2 Installing

Install in reverse order of removal.

1.8.1 Removing

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Move seat to frontmost position.

Disconnect wiring harness from seat frame, if part of original equipment.

Remove bolt -1- (20 Nm).

Note

The bolt is microencapsulated and must be renewed each time it is loosened.

Before a new bolt is installed, the thread of the corresponding nut must be cleaned.

Pull belt buckle -2- out of mounting in seat rail -arrow-.

1.8.2 Installing

Install in reverse order of removal.

The seat belt system must be inspected systematically after every accident! If damage is determined at any of the points to be checked, customer must be informed regarding necessity of changing belts.

Check points:

Checking belt webbing

Checking inertia reel (locking mechanism)

Visually checking belt buckle

Checking operation of belt buckle

Checking belt guide fittings and latch plate

Checking securing parts and anchorage points

Pull belt completely out of inertia reel or lap belt adjustment plate.

Inspect belt straps for soiling and, if necessary, wash with mild soap solution (also refer to Owner’s Manual).

If either of the following illustrated damage examples (1 and 2) are found on accident vehicle – renew seat belt complete with belt buckle and belt height adjustment.

If damage as illustrated under points 1, 2, 3 and/or 4 is determined on a vehicle which has not been involved in an accident, it is sufficient to renew damaged belt only.

Belt webbing cut, torn or chafed.

Torn webbing loops on edge belt.

Burn marks from cigarettes or similar.

One edge of belt deformed or wavy.

The inertia reel has two locking functions.

The first locking function is triggered by the belt being jerked out of reel (belt extraction acceleration).

Checking

Pull belt out of inertia reel with firm jerk.

No locking effect – renew seat belt complete with buckle.

If difficulties are experienced when belt is extended or retracted, first check whether position of inertia reel has been altered.

The second locking function is triggered by a change in vehicle speed (vehicle-dependent locking function). Vehicle must be moved over a flat level surface for this.

Checking

Put on seat belt.

Accelerate vehicle to 20 km/h and then carry out emergency braking with foot brake.

If seat belt is not locked by locking mechanism during braking procedure, renew seat belt complete with buckle.

WARNING

For safety reasons, the road test should be carried out on a traffic-free stretch to ensure that other road users are not endangered.

Inspect belt buckle for cracks and chips.

If damage is determined, renew seat belt complete with belt buckle.

Checking buckle:

Push latch plate into belt buckle until it engages audibly. Check whether locking mechanism is properly engaged by pulling firmly on belt webbing.

If latch plate fails even once to engage properly in belt buckle during at least 5 tests, renew seat belt complete with belt buckle.

Checking release mechanism:

Release seat belt by pressing button on belt buckle with finger pressure.

When belt is slack, latch plate must spring out of belt buckle on its own.

Carry out test at least 5 times. If latch plate fails even once to spring out of buckle, renew seat belt complete with belt buckle.

WARNING

Under no circumstances whatsoever may lubricant be used to eliminate noise or stiffness in belt buckle buttons.

Plastic-coated hardware show fine, parallel scoring after stress on belt system (when belt was fastened during accident). (On the other hand, wear caused by frequent belt use can be recognized by smooth wear, free of lines).

Inspect for deformation, fracturing and cracks in plastic.

If scoring and/or damage is determined, renew seat belt complete with belt latch.

Latch plate deformed (stretched)

Height adjuster non-functional

Anchorage points (seat, pillars, vehicle floor) distorted or thread damaged

If damage is determined on these parts, renew seat belt complete with belt buckle.

Renew anchorage points.

Note

In case of damage resulting not from an accident, but for example, from wear, only the part which is actually damaged need be renewed.

Child seat anchors must be checked for damage and deformation after an accident.

Child seat anchors welded to body must not be repaired or straightened.

If child seat anchors bolted to body are damaged or deformed, they must be renewed.

Removal wedge -3409-

The automatic anti-dazzle interior mirror darkens continuously when the driver is blinded from behind.

It consists of a mirror element and electrics with two photo sensors.

The photo sensors of the electronics detect the light incidence from the front and the rear.

If the light incidence is greater from the rear than from the front, the electronics apply voltage to the conductive coating.

The applied voltage changes the colour of the electrolyte. The greater the voltage, the darker the electrolyte. Therefore, the incident light is reflected to a lesser degree.

Selecting reverse gear switches off the anti-dazzle function. Consequently, one can, for example, reverse out of a dark garage with the aid of the interior mirror.

Release lever -T10039-

Removal wedge -3409-

Removal wedge -3409-

Removal wedge -3409-

Removal pliers -3392-

Release tool -T10236-

Removal wedge -3409-

Removal pliers -3392-

Removal wedge -3409-

Removal pliers -3392-

Press retaining clip -1- forward in direction of travel -arrow- and pull window crank -2- from shaft -3-.

Installation is carried out in reverse order of removal.

Note

After reinstallation, the window crank handle on the right side must be positioned at “5 o’clock” when window is closed.

After reinstallation, the window crank handle on the left side must be positioned at “7 o’clock” when window is closed.

This equates to an installation angle of 30° -angle α-.

Deviation between window cranks must be no more than 6°.

Remove dash panel end trim (refer to page 60).

Remove A-pillar centre trims (refer to page 224)

Remove airbag emblem -1- and remove bolt -2- (4 Nm).

Pull lower section of trim -arrow A- out of securing clips -3-.

Release trim from door seal beading.

Pull trim out of forward mountings -arrow B-.

Pull rear section of trim out of dash panel -arrow C-.

Note

When reinstalled, airbag emblem -1- must be renewed.

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

Install in reverse order of removal.

Removing

Remove dash panel end trim (refer to page 60).

Pull upper part of trim -1- out from mountings in body -arrow A-.

Pull out trim upwards from A-pillar lower trim -arrow B-.

Installing

Install in reverse order of removal.

4.3.1 Removing

Release sill panel moulding from body, in area of transition to lower A-pillar moulding:

Two-door (refer to page 81)

Four-door (refer to page 82)

Remove dash panel end trim (refer to page 60).

Remove bonnet operating lever (refer to Rep. Gr. 55).

Remove clip -2-.

Release trim from body -arrow A-.

Release trim from door seal beading.

Pull trim out of mountings -arrow B-.

4.3.2 Installing

Install in reverse order of removal.

Note

Before installing clip, check clip -2- for damage and renew if necessary.

4.4.1 Removing

Release sill panel moulding from body, in area of transition to lower A-pillar moulding:

Two-door (refer to page 81)

Four-door (refer to page 82)

Remove dash panel end trim on front passenger side (refer to page 60).

Release trim from body -arrow A-.

Release trim from door seal beading.

Pull trim out of mountings -arrow B-.

4.4.2 Installing

Install in reverse order of removal.

4.5.1 Removing

Remove airbag emblem -1- and remove bolt -2- (4 Nm).

Note

When reinstalled, airbag emblem -1- must be renewed.

Pull lower section of trim out of mountings in body -arrow A-.

Release trim from door seal beading.

Pull trim out of upper mountings -arrow B-.

4.5.2 Installing

Installation is carried out in reverse order of removal.

Note

When installing, the belt adjuster slide -4- and the button of the trim -3- must be in the same position.

Before installing, check clip for damage and renew if necessary.

4.7.1 Removing

Switch off ignition.

4-door, vehicles ▸06/2005

Remove bench seat (refer to page 304).

Remove side padding (4-door):

with rear side airbags (refer to page 306)

with no rear side airbags (refer to page 307)

Remove wheel housing liner (4-door) (refer to page 84).

4-door, vehicles with rear side airbag, 06/2005▸

Remove side padding (4-door):

with rear side airbags (refer to page 306)

Remove wheel housing liner (4-door) (refer to page 84).

4-door, vehicles without rear side airbag, 06/2005▸

Remove wheel housing trim, 4-door, without rear side airbag (refer to page 85).

2-door

Remove upper B-pillar trim. Belt end anchor or anchor rail for front seat belt need not be removed (refer to page 228).

Remove bench seat (refer to page 304).

Remove backrest (refer to page 305).

Remove side panel trim (refer to page 233).

All vehicles

Remove luggage compartment cover side support (refer to page 241).

Remove roof end strip (refer to page 246).

Remove airbag emblem -1- and remove bolt -2- (4 Nm).

Note

When reinstalled, airbag emblem -1- must be renewed.

Remove nut -3- (1.5 Nm).

Release trim from stud of nut -3- -arrow A-.

Release trim from mountings -arrow B- and from door seal beading.

Pull trim upwards out of mountings in body -arrow C-.

4.7.2 Installing

Install in reverse order of removal.

Removal and installation is described for the right vehicle side. Follow same instructions for the left side as appropriate.

3.1.1 Removing

Pull rear bench seat out of front anchor positions (refer to page 304).

Note

Removing rear bench seat completely is not necessary.

Pull sill panel moulding -1- out of mountings in sill, the side panel and beading in door seal.

Note

Before installing, check the seven fasteners for damage and renew if necessary.

Removal and installation is described for the left vehicle side. Follow same instructions for the right side as appropriate.

3.2.1 Removing

Pull rear bench seat out of front anchor positions (refer to page 304).

Note

Removing rear bench seat completely is not necessary.

Pull 4-door wheel housing trim out of mountings in transition area to sill panel moulding.

Pull sill panel moulding out of front area of sill and beading of door seal.

Detach guide -1- from lower B-pillar trim.

Pull sill panel moulding out of rear area of sill and beading of door seal.

Detach guide -2- from lower B-pillar trim.

Open tab -3- and guide seat belt out through.

Note

Before installing, check 6 securing clips for damage and renew if necessary.

3.2.2 Installing

Install in reverse order of removal.

3.3.1 Removing

Remove rear bench seat (refer to page 304).

Remove side padding (4-door):

With rear side airbags (refer to page 306)

Without rear side airbag, ▸06/2005 (refer to page 307).

Remove the two bolts -1- (1.2 Nm).

Detach clips -2- from body flange.

Pull trim -3- out from beading of door seal -4-.

Pull moulding out of mountings in sill panel moulding -5-.

Pull trim out forwards under C-pillar trim.

3.3.2 Installing

Install in reverse order of removal.

Release lever -T10039 –

4.1.1 Removing

Fold down grab handle and open the two cover caps -1- and -2- using a small screwdriver.

Remove the two bolts -3- (2 Nm) and remove grab handle.

4.1.2 Installing

Install in reverse order of removal.

Airbag adapter -VAS 6229-

Airbag adapter -VAS 6281-

Remove front seats (refer to page 260).

Remove accelerator pedal module (refer to Rep. Gr. 20).

Remove centre console:

Base version (refer to page 6)

Highline version (refer to page 15)

Remove dash panel end trim (refer to page 60).

Remove bonnet operating lever (refer to Rep. Gr. 55).

Remove sill mouldings:

Two-door (refer to page 81)

Four-door (refer to page 82)

Remove lower A-pillar trims:

Driver’s side (refer to page 225)

Passenger side (refer to page 227)

Unscrew bolt -1- (1.5 Nm) and pull footrest cover -2- upwards out of mountings in floor panel.

Right-hand drive vehicles only.

Pull clip -1- out and remove stud -2-.

Loosen stud -3- from threaded pin.

Pull footrest cover -4- up out of mountings in floor panel.

Two-door vehicles and vehicles with electric seat adjustment only

Remove cover -1- and remove bolt -2- (1 Nm).

Remove bracket -3- from seat rail -4-.

All vehicles

Cut floor covering at both -dot-dash lines- in area of handbrake console.

Remove floor covering from vehicle.

Install in reverse order of removal.

Airbag adapter -VAS 6229-

Airbag adapter -VAS 6281-

Assembly tool -3399-

Engine and gearbox support -VAS 6095-

Seat repair stand -VAS 6136-

Pop-rivet pliers -VAS 5072-

Removal wedge -3409-

Follow safety precautions when working on the airbag.

Remove drawer from seat, if fitted.

Move seat to foremost position using longitudinal adjustment.

Remove bolts -3- and -4-.

Move seat to rearmost position using longitudinal adjustment.

Disconnect vehicle battery (refer to Rep. Gr. 27).

Remove cover cap -5- from coupling station.

WARNING

Electrostatic discharges may result in unintentional triggering of airbag. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting the igniter and earth wires. This can be done by briefly touching the body or striker plate of the door.

Depending on vehicle equipment, disconnect seat wiring harness from coupling station.

Connect airbag adapter -VAS 6229- or airbag adapter -VAS 6281- to side airbag wiring harness -6-.

Remove bolts -1- and -2-.

Release wiring harness from mountings in floor.

Caution

If seat is lifted out of vehicle or transported, it must not, in order to prevent damage, be gripped by attaching parts such as, e.g. belt buckle, lever for seat longitudinal adjustment, lever for seat height adjustment or seat trim panels.

Insert right hand between backrest and seat cushion, grip front end of seat cushion with left hand and lift seat out of vehicle.

Lift seat through front door opening.

Locate seat on centralizing pins, mounted on sides of tunnel, and into respective openings in floor.

Tighten bolt -1- (40 Nm).

Tighten bolt -2- (40 Nm).

WARNING

If a thread in seat cross member mounting plate is damaged on seat installation, reworking damaged threads is prohibited! In this case, the seat cross member mounting plate must be replaced.

If seat cross member mounting plate threads have been damaged:

Replace the affected seat cross member mounting plate (refer to Body Repairs; Rep. Gr. 51).

Remove bolt -1- (2.5 Nm).

Using a small screwdriver, press metal tab of fastener -2- inwards and pull handle off -3- from adjustment lever -4-.

Lever out backrest trim -1- from backrest in area of retainers -arrows- using removal wedge -3409- .

Pull backrest trim -1- slightly to rear. Slide backrest trim out of mountings in backrest in area of guides -2-.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove right side trim on seat (refer to page 276).

Remove left side trim on seat (refer to page 263).

Remove front seat backrest (refer to page 281).

Secure backrest to seat repair stand -VAS 6136- .

Remove cover and padding from front seat backrest (refer to page 315).

Remove the two bolts -1- and remove adjustment knob -2- from backrest frame.

Drill out rivet -3-.

Unhook both lumbar support frame upper wires -4- from backrest frame.

Remove lumbar support frame from backrest frame -5-.

Install in reverse order of removal.

1.20.1 Removing

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove front left bucket seat trim (refer to page 265).

Remove front belt buckle:

Two-door (refer to page 98)

Four-door (refer to page 100)

Remove front right bucket seat trim (refer to page 277).

Remove front bucket seat backrest (refer to page 282).

Remove cover and padding from front bucket seat cushion (refer to page 312).

In front area, remove the two bolts -1- (24 Nm).

In rear left area of seat frame, remove bolt -2- (24 Nm).

In rear right area of seat frame, remove bolt -3- (24 Nm).

Note

The bolts -1- to -3- are microencapsulated and must be renewed each time they are loosened.

Before new bolts are installed, the threads of the corresponding holes must be cleaned.

Remove backrest from seat frame.

1.20.2 Installing

Install in reverse order of removal.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove front left bucket seat trim (refer to page 265).

Remove front belt buckle:

Two-door (refer to page 98)

Four-door (refer to page 100)

Remove front right bucket seat trim (refer to page 277).

Remove front bucket seat backrest (refer to page 282).

If fitted, disconnect electric connectors for heating backrest on underside of seat pan.

Remove two bolts each on left and right -1- and -2- (34.5 Nm).

Note

The bolts are microencapsulated and must be renewed each time they are loosened.

Before new bolts are installed, the threads of the corresponding holes must be cleaned.

Remove backrest from seat frame.

Install in reverse order of removal.

Remove left side trim on seat (refer to page 263).

Remove bolt -2- (2 Nm).

Remove the three bolts -3- (2 Nm).

Remove mounting -4- from seat frame.

Install in reverse order of removal.

Remove front seat (refer to page 260).

Remove front belt buckle:

Two-door (refer to page 98)

Four-door (refer to page 100)

Remove right trim on seat (refer to page 276).

Detach retaining bar -1- from mounting.

Unhook retaining straps -2- on both sides of seat.

Unhook retaining bars -3- from mountings on both sides of seat.

Unhook retaining bar -4- from mounting on front of seat.

Roll up cover on outer sides working around perimeter.

Install in reverse order of removal.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove right side trim on seat (refer to page 276).

Remove left side trim on seat (refer to page 263).

Remove front seat backrest (refer to page 281).

Secure backrest to seat repair stand -VAS 6136- .

Remove cover and padding from front seat backrest (refer to page 315).

Remove two bolts each on left and right -1- and -2- (34.5 Nm).

Note

The bolts are microencapsulated and must be renewed each time they are loosened.

Before new bolts are installed, the threads of the corresponding holes must be cleaned.

Remove backrest from seat frame.

Install in reverse order of removal.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove front left bucket seat trim (refer to page 265).

Remove front belt buckle:

Two-door (refer to page 98)

Four-door (refer to page 100)

Remove front right bucket seat trim (refer to page 277).

Remove front bucket seat backrest (refer to page 282).

Remove cover and padding from front bucket seat cushion (refer to page 312).

In front area, remove the two bolts -1- (24 Nm).

In rear left area of seat frame, remove bolt -2- (24 Nm).

In rear right area of seat frame, remove bolt -3- (24 Nm).

Note

The bolts -1- to -3- are microencapsulated and must be renewed each time they are loosened.

Before new bolts are installed, the threads of the corresponding holes must be cleaned.

Remove backrest from seat frame.

Install in reverse order of removal.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove front left bucket seat trim (refer to page 265).

Remove front belt buckle:

2-door (refer to page 98)

4-door model (refer to page 100)

Remove front right bucket seat trim (refer to page 277).

Remove front bucket seat backrest (refer to page 282).

Remove cover and padding from backrest of front bucket seat (refer to page 320).

Unscrew screws -1-.

Take upper shell of backrest release -2- off backrest shell in -direction of arrow-.

Unclip Bowden cable -2- from locking device -arrow A-.

Remove Bowden cable -2- from locking device -arrow B-.

Note

Carry out following procedures on both sides.

Drill out rivets -1- on backrest side rail -3-.

Unscrew bolts -2- (24 Nm) and fold backrest side rail -3- upwards in -direction of arrow-.

Note

The bolts are microencapsulated and must be renewed each time they are loosened.

Before new bolts are installed, the thread of the corresponding fitting must be cleaned.

Pull Bowden cable -1- out of retainer.

Slide Bowden cable eye -2- downwards in -direction of arrow- and remove cable from pin -4-.

Remove remains of blind rivet -3-.

Remove Bowden cable -1- through openings in backrest shell -2-.

Install in reverse order of removal.

Note

To install blind rivets, use pop rivet pliers -VAS 5072- .

Note

Removal and installation are described for the left vehicle side. Follow same instructions for the right side as appropriate.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove right side trim on seat (refer to page 276).

Remove left side trim on seat (refer to page 263).

Remove front seat backrest (refer to page 281).

Secure backrest to seat repair stand -VAS 6136- .

Remove cover and padding from front seat backrest (refer to page 315).

Remove the two bolts -1- and remove adjustment knob -2- from backrest frame.

Drill out rivet -3-.

Unhook both lumbar support frame upper wires -4- from backrest frame.

Remove lumbar support frame from backrest frame -5-.

Install in reverse order of removal.

1.28.1 Removing

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove right side trim on seat (refer to page 276).

Remove left side trim on electrically adjustable seat (refer to page 267).

Remove bar and operating lever for front seat (refer to page 275).

Remove front seat drawer mounting (refer to page 271).

Remove front seat backrest (refer to page 281).

Remove cover and padding, front seat cushion (refer to page 309).

Unscrew bolts -1- and -2- on right.

Remove bolt -3- in rear area.

Note

Bolt -3- points from inside out when installed.

Remove bolt -4- in front area.

Release seat pan -5- from longitudinal seat adjustment -6-.

Installation is carried out in reverse order of removal.

If seat base currently fitted is to be renewed, the replacement part is a seat base from the “Sportline” equipment level. If this seat base is to be installed in a vehicle with a different equipment level, bars -1- and -2- must be removed.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove right side trim on seat (refer to page 276).

Remove left side trim on electrically adjustable seat (refer to page 267).

Remove bar and operating lever for front seat (refer to page 275).

Remove front seat drawer mounting (refer to page 271).

Remove front seat backrest (refer to page 281).

Remove cover and padding, front seat cushion (refer to page 309).

Separate wiring harness -1- from tilt angle adjustment -2-.

Remove bolt -3-.

Remove two bolts each -4- and -5-.

Detach tilt angle adjustment -2- from seat frame.

Install in reverse order of removal.

Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Remove front seat (refer to page 260).

Secure seat to seat repair stand -VAS 6136- .

Remove right side trim on seat (refer to page 276).

Remove left side trim on electrically adjustable seat (refer to page 267).

Remove bar and operating lever for front seat (refer to page 275).

Remove front seat drawer mounting (refer to page 271).

Remove front seat backrest (refer to page 281).

Remove cover and padding, front seat cushion (refer to page 309).

Unscrew bolt -1- in rear area from seat frame.

Note

Bolt -1- points from inside out when installed.

Separate wiring harness -2- from height adjustment -3-.

Remove the two bolts -4-.

Detach height adjustment -3- from mountings in seat frame.

Install in reverse order of removal.

Unclip the four guides -1- from child seat anchorages -2-.

Pull front section of bench seat -3- upwards out of the two mountings -4- -arrows A-.

Push bench seat to rear -arrow B-.

Pull rear section of bench seat upwards.

Remove bench seat from vehicle.

Install in reverse order of removal.

Remove bench seat (refer to page 304).

Fold back floor covering in area of backrest centre mounting -4-.

Remove trim -1- from backrest centre mounting.

Remove bolt -2- (9 Nm).

Release clamp -3- from backrest centre mounting.

Lift right backrest -5- out of backrest centre mounting and pull backrest off pin -6-.

Remove bolt -8- (40 Nm) and remove belt buckle -9- from floor.

Remove right-hand backrest from vehicle.

Lift left-hand backrest -7- out of backrest centre mounting and pull backrest off pin.

Install in reverse order of removal.

Assembly overview

1 – Bolt (40 Nm)

2 – Belt buckle

3 – Hexagon nut (40 Nm)

4 – Belt inertia reel

5 – Console

1.10.2 Removing

Remove bench seat (refer to page 304).

Remove backrest (refer to page 305).

Remove cover and padding from seat backrest (refer to page 325).

Remove bolt -1- (40 Nm) and remove belt buckle -2- from body.

Remove hexagon nut -3- (40 Nm) and remove belt inertia reel -4- from console -5-.

Guide belt buckle -2- through console -5-.

Install in reverse order of removal.

1.11.1 Removing

Remove bench seat (refer to page 304).

Remove backrest (refer to page 305).

Remove bolt -1- (40 Nm) and remove lap belt -2- from body.

1.11.2 Installing

Install in reverse order of removal.

1.12.1 Removing

Remove bench seat (refer to page 304).

Remove backrest (refer to page 305).

Remove bolt -1- (40 Nm) and remove double belt buckle -2- from body.

1.12.2 Installing

Install in reverse order of removal.

6.1.1 Removing

WARNING

Observe the general safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) (refer to page 90)

Disconnect vehicle battery (refer to Rep. Gr. 27).

Remove door outer panel (refer to Rep. Gr. 57).

Disconnect wiring harness -1- from crash sensor -3-.

Remove the two bolts -2- (2.5 Nm).

6.1.2 Installing

Install in reverse order of removal.

Switch ignition on.

WARNING

Ensure that nobody is in the vehicle.

Reconnect vehicle battery (refer to Rep. Gr. 27).