VOLKSWAGEN GOLF VARIANT 2007 (09) PDF Document

The bolts -2- have a specified torque of 8 Nm when removing and installing the lock carrier with add-on parts.

The bolts -3- have a specified torque of 60 Nm when removing and installing the lock carrier with add-on parts.

To move the VOLKSWAGEN GOLF VARIANT 2007 to the service position, the following steps should be taken:

Step 1. Remove front bumper cover.

Step 2. Remove air duct from lock carrier -1-.

Step 3. Unhook Bowden cable from coupling for bonnet release.

Step 4. If the vehicle has a charge air cooler, disconnect pressure hoses.

Step 5. Unscrew horn -4- with bracket on the right side of the longitudinal member.

Step 6. Pull connector off high-pressure sender -G65-.

Step 7. Remove bolts -3- from the left and right longitudinal members.

Step 8. Attach special tool guide pins -T10093- to the left and right longitudinal members.

Step 9. Remove bolts -2- on the left and right from the upper part of the lock carrier -1-.

Step 10. The lock carrier -1- can be pulled forwards on the guide pins -T10093-.

Note: If necessary, disconnect the upper coolant hose from the radiator, but drain the coolant first.

To move the VOLKSWAGEN GOLF VARIANT 2007 from the service position, install in the reverse order of removal.

Align the lock carrier on the longitudinal members and between the wings.

When releasing pressure hoses on the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Release push-on coupling -1- and pull pressure hose -2- in the direction of the arrow out of the coupling.

Ensure that the charge air cooler pressure hoses are properly engaged again.

Ensure that hoses and lines must not be pinched.

If necessary, replenish coolant.

During installation of pressure hoses, ensure that the push-on coupling engages audibly.

A crucial note regarding the removal of the lock carrier on the VOLKSWAGEN GOLF VARIANT 2007 is that because the lock carrier is a safety-relevant component, it must not be repaired. If damaged, the lock carrier must be renewed.

The steps for removing the lock carrier with add-on parts on the VOLKSWAGEN GOLF VARIANT 2007 are:

Step 1. Set the lock carrier with add-on parts -1- to the service position.

Step 2. Disconnect all electrical connectors.

Step 3. Drain coolant and disconnect coolant hoses.

Step 4. Disconnect lines for the condenser.

Step 5. Together with a second mechanic, unscrew guide pins -T10093- from the left and right longitudinal member and lift the lock carrier out -1-.

Caution: Do not start the engine if the air conditioning system and/or the coolant system lines are disconnected.

When installing the lock carrier with add-on parts on the VOLKSWAGEN GOLF VARIANT 2007:

Install in reverse order of removal.

Ensure that all connectors and hose connections are properly installed.

Align the lock carrier on the longitudinal members and between the wings.

Notes regarding the removal and installation of the front wing on the VOLKSWAGEN GOLF VARIANT 2007:

Only the left side is shown; the right side is similar.

The removal and installation sequence is only described for the left wing; the removal and installation of the right wing is similar.

The specified torque for the bolts -2- (A-pillar, side member, wing bracket, wing connection piece) when removing and installing the wing on the VOLKSWAGEN GOLF VARIANT 2007 is 6 Nm.

The specified torque for the hexagon nut -6- on the wing connection piece when removing and installing the wing bracket on the VOLKSWAGEN GOLF VARIANT 2007 is 6 Nm.

To install the wing bracket -1- on the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Install the wing bracket -1-.

Step 2. Specified torque for bolts -2-: 6 Nm.

Step 3. The wing and wing bracket must be aligned with the bonnet and bumper cover.

The procedure for removing the bonnet on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the left and right washer jets.

Step 2. Unclip line -2- from the bonnet hinge -3- and bonnet -5-.

Step 3. Pull line -2- out through the aperture in bonnet -5-.

Step 4. Loosen the hexagon nuts -1- on the left and right (do not remove).

Step 5. Disconnect the gas strut -4- from the bonnet -5-.

Step 6. Remove the hexagon nuts -1- and lift the bonnet -5- out of the bonnet hinges -3-.

Further dismantling requires the assistance of a second mechanic.

The specified torque for the bonnet hexagon nut when installing the bonnet on the VOLKSWAGEN GOLF VARIANT 2007 is 22 Nm.

The specified torque for ball-head pins -3- and -4- when removing the gas strut on the VOLKSWAGEN GOLF VARIANT 2007 is 22 Nm.

When reusing a gas strut on the VOLKSWAGEN GOLF VARIANT 2007, proceed with care. The spring clip must not be levered completely out of the ball socket, as it will otherwise be damaged. The gas strut will spring out of mounting, causing damage or injury to the operator.

When releasing gas from a gas strut on the VOLKSWAGEN GOLF VARIANT 2007, take the following precautions:

Step 1. Clamp the gas strut in a vice in the area marked -x- = 50 mm (2 in).

Warning: Clamp the gas strut only within area -x-; otherwise there is a danger of accident!

Step 2. Saw through the cylinder of the gas strut within the first third of the cylinder’s overall length using the piston rod end of the cylinder as a reference point.

Notes to observe:

Wear eye protection when sawing.

Cover the area of the saw cut with a cloth.

Dispose of oil and cloth via existing disposal channels.

The removal and installation sequence for the lid hinge on the VOLKSWAGEN GOLF VARIANT 2007 is only described for the left hinge; the removal and installation of the right hinge is similar.

The specified torque for the lid hinge bolts -2- when installing the lid hinge on the VOLKSWAGEN GOLF VARIANT 2007 is 22 Nm.

To remove the insulation on the bonnet of the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Lever the retaining clips -1- out of the insulation -2- using the removal lever -80-200-.

Step 2. Pull the insulation -2- out of the elongated holes.

To install the insulation on the bonnet of the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Push the insulation -2- underneath the gas strut and place the assembly tongues in the elongated holes.

Step 2. Engage all retaining clips -1- in the insulation -2-.

When installing insulation -2-, ensure that the retaining clips -1- are fitted with the wider side outwards.

The specified torque for bolts -4- when installing the bonnet lock on the VOLKSWAGEN GOLF VARIANT 2007 is 12 Nm.

Before closing the bonnet after installing the bonnet lock on the VOLKSWAGEN GOLF VARIANT 2007, always check the function of the release lever and Bowden cable.

The procedure for disconnecting the Bowden cable on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Open the bonnet.

Step 2. Unclip the Bowden coupling -1- above the right headlight for the lock carrier -2-.

Step 3. Open the Bowden cable coupling -1- upwards and remove the Bowden cable -3- in the direction of the arrow out of the Bowden cable coupling.

Note: When installing, ensure that the Bowden cable sleeve is inserted correctly and the coupling engages.

Before closing the bonnet, check the function of the release lever and Bowden cable.

The procedure for adjusting the bonnet on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. For initial adjustment of the bonnet -1-, the vehicle must be standing on the ground and the arrester must be removed.

Step 2. Remove latch hook -9-.

Step 3. Disconnect the gas strut -2- from the bonnet -1-.

Step 4. The bonnet -1- can be centered between the wings by loosening the hexagon nuts -5- and bolt -3- (do not remove) on the left and right bonnet hinges -4-.

Step 5. The bonnet -1- can be adjusted in height to the wings at the rear by means of the adjustment screw -6- on the left and right.

The stop buffers -7- (Qty. 2) are not used for adjustment; they have the function of stabilizing and damping the bonnet -1-.

Step 6. The front part of the bonnet -1- can be adjusted to the wing height by using the adjustment buffers -8- (Qty. 2).

Ensure that gaps are uniform.

Step 7. After refitting or adjustment work, apply corrosion protection to the bonnet hinge -4-, hexagon nuts -55- and bolts -3-.

Step 8. After adjusting the bonnet -1-, install and adjust the arrester.

If gaps change when the bonnet is closed on the VOLKSWAGEN GOLF VARIANT 2007, minor corrections can be made via the bonnet lock and arrester. To do this, remove the radiator grille.

The procedure for removing the release lever on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Pull the operating lever -1- and release the bonnet.

Step 2. Insert a small screwdriver in the gap between the release lever -1- and clip -2-.

Step 3. Lever clip -2- out of the release lever -1- and pull off the release lever.

To install the release lever on the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Slide clip -2- completely into the release lever -1-.

Step 2. Press the release lever -1- onto the mounting in the mounting bracket and fasten the release lever.

Before closing the bonnet, check the function of the release lever and Bowden cable.

The specified torque for the rear lid hexagon nut when installing the rear lid (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is 22 Nm.

The specified torque for the lid hinge bolts -2- when installing the lid hinge on the VOLKSWAGEN GOLF VARIANT 2007 is 22 Nm.

The specified torque for hexagon nuts when installing the lid lock on the VOLKSWAGEN GOLF VARIANT 2007 is 8 Nm.

To install the rear lid seal -1- on the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Align the rear lid seal -1- so that the vulcanised point -arrow- is located in the middle of the left tail light cluster.

Step 2. Push the seal -1- evenly onto the body flange -2-.

Notes regarding removing and installing rear lid seals on the VOLKSWAGEN GOLF VARIANT 2007:

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

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

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 the sides of the seal together before refitting.

The specified torque for bolts -3- for the registration plate carrier on the VOLKSWAGEN GOLF VARIANT 2007 is 4 Nm.

The instructions for adapting keys with remote control on the VOLKSWAGEN GOLF VARIANT 2007 are:

Step 1. Keys with remote control are adapted using the vehicle diagnosis, testing and information system -VAS 5051-.

Step 2. Select “guided fault finding” in vehicle diagnostic, testing and information system -VAS 5051-.

Step 3. Using the GoTo key, select “Function/component selection” and the following menu items in succession:

Body (Repair group 01; 27; 50 – 97)

Internal/external installations (Repair group 01; from 55 77)

01 – Self-diagnosis

46 – Convenience system central module

Functions

Adaption

The procedure for removing the battery for the folding key with remote control on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Insert a screwdriver in the slot between the transmitter unit -1- and the key -2-.

Step 2. Twist the screwdriver in the direction of the arrow to separate the transmitter unit from the key.

Step 3. Press the upper part of the transmitter unit and the lower part of the transmitter unit apart in the direction of the arrow.

Step 4. Unclip the battery -1- from the retainers -2- with a screwdriver in the direction of the arrow.

Notes for installing the battery for the folding key with remote control on the VOLKSWAGEN GOLF VARIANT 2007:

Note the polarity and correct position when installing the battery.

Place battery -1- in the transmitter unit -2- with the positive terminal downwards (the positive terminal is marked on the housing).

Engage the battery in the lower part of the transmitter unit by pressing down lightly.

Fit the upper part of the transmitter unit and the lower part of the transmitter unit together (do not damage the seal).

Clip the transmitter unit to the key.

The special tools and workshop equipment required for the rear door (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Torque wrench -V.A.G 1331-

The specified torque for the rear lid hexagon nut when removing and installing the rear lid (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is 22 Nm.

The procedure for removing the rear lid (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Open the rear lid.

Step 2. Remove the rear lid trim.

Step 3. Disconnect connectors -1- and pull the wiring -2- with the rubber grommet out of the lid.

Step 4. Loosen the hexagon nuts -3- on the left and right lid hinges (do not unbolt completely).

Step 5. Detach the gas struts -4- on the left and right of the rear lid.

Step 6. Now, and only now, unbolt bolts -3- and remove the rear lid.

Further dismantling requires the assistance of a second mechanic.

The procedure for adjusting the rear lid on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. The vehicle must be standing on the ground to perform the basic adjustment of the rear lid.

Step 2. The rear lid lock is bolted directly to the rear lid and does not have elongated holes, so it cannot be adjusted.

Step 3. The stop buffers -3- on the left and right are not a means of adjustment; their purpose is to stabilize and dampen the rear lid -1-.

Step 4. The rear lid is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or does not stand proud, and all contours align when the rear lid is closed.

Step 5. The rear lid must engage in the striker pin -4- without excessive force.

Step 6. Use setting gauge -3371- to check or set gap dimensions.

Step 7. Remove the gas strut.

Step 8. Adjust the rear lid on the rear lid hinges by loosening bolts -Item 9-.

Step 9. Adjust the rear lid with the rear lid hinges by loosening the hexagon nut -Item 6-.

Step 10. Adjust the adjustment buffer.

The process for adjusting the adjustment buffer for the rear lid on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Loosen the grub screw -1- until it is visible in the rubber buffer.

Step 2. Pull the detent slide out of the adjustment buffer.

Step 3. Adjust the detent slide to dimension -a- = 12.5 mm.

Step 4. Close the rear lid to the detent position with light pressure at the centre of the lid.

Step 5. Open the rear lid again.

Step 6. Screw in the adjustment buffer clamping screw -1- to a depth of dimension -a – = 25 mm.

Step 7. Check the setting.

The specified torque for bolts -1- when installing the striker pin on the rear lid (saloon) of the VOLKSWAGEN GOLF VARIANT 2007 is 23 Nm.

The installation notes for the fuel tank flap unit (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 are:

The mounting part -5- has been pushed in.

Feed the drain hose -3- through the aperture in the tank flap unit -2- and pull the drain hose through as far as possible.

Guide the drain hose into the side panel.

With the hinge side leading, guide the tank flap unit -2- into the side panel.

Swivel the tank flap unit completely onto the side panel.

Make sure that the tank flap unit -2- locking devices engage correctly in the side panel at the top and bottom.

Pull the rubber part of the tank flap unit over the filler neck and tighten bolt -4-.

The specified torque for bolt -4- is 1.5 Nm.

Perform a functional check of the release components.

The procedure for removing the tank filler flap locking motor -V155- on the VOLKSWAGEN GOLF VARIANT 2007 (saloon) is:

Step 1. Remove the luggage compartment side trim on the right.

Step 2. Disconnect connector -8- on the tank filler flap locking motor -V155- -9-.

Step 3. Loosen bolts -10-.

Step 4. Pull the tank filler flap locking motor -V155- -9- together with the release rod -7- out of the seal -6- and fitting -5-.

The installation steps for the tank filler flap locking motor -V155- on the VOLKSWAGEN GOLF VARIANT 2007 (saloon) are:

Step 1. Install in reverse order of removal.

Step 2. Perform a functional check of the release components.

The procedure for removing the tank flap unit (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Open the fuel tank flap.

Step 2. Remove the tank cap.

Step 3. Remove bolt -4-.

Step 4. Pull the rubber part of the tank flap unit -2- off the fuel tank filler neck -1-.

Step 5. Pull the tank flap unit -2- with the drain hose -3- to the rear and swing the fuel tank flap unit out of the side panel.

Note: If the fuel tank filler flap does not open, it can be opened by hand using the release rod -7-. Remove the rear right luggage compartment trim for this.

The procedure for installing the tank flap unit (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Feed the drain hose -3- through the aperture in the tank flap unit -2- and pull the drain hose through as far as possible.

Step 2. Guide the drain hose into the side panel.

Step 3. With the hinge side leading, guide the tank flap unit -2- into the side panel.

Step 4. Swivel the tank flap unit completely onto the side panel, ensuring that the tank flap unit -2- locking devices engage correctly in the side panel at the top and bottom.

Step 5. Pull the rubber part of the tank flap unit over the filler neck and tighten bolt -4-.

The specified torque for bolt -4- is 1.5 Nm.

Step 6. Perform a functional check of the release components.

The procedure for installing the tank filler flap locking motor -V155- on the VOLKSWAGEN GOLF VARIANT 2007 (Variant) is:

Step 1. Install in reverse order of removal.

Step 2. Perform a functional check of the release components.

Notes for removing and installing door seals on the VOLKSWAGEN GOLF VARIANT 2007:

During production, a sealant is applied to the door inner seals, which are 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 the sides of the seal together before refitting.

To install the door inner seal on the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Align the door inner seal so that the vulcanised point -arrow b- is located at the height of the lower hinge.

Step 2. Start installing the door inner seal at the top radius -arrow a- of the door aperture.

Notes for removing and installing the door outer seal on the VOLKSWAGEN GOLF VARIANT 2007:

Removal and installation are described only for the right door outer seal. Removal and installation of the left door outer seal are similar.

Remove the protective backing immediately before installation.

The working temperature is approximately 20 °C.

Adhesive remover -D 002 000 10- must be used exclusively.

The door outer seal must be bonded in place immediately after cleaning.

The specified torque for bolts -2- when adjusting the striker pin on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is 20 Nm.

The warning associated with adjusting the striker pin on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is: Only use this adjustment to adjust the door inwards or outwards; never use for vertical adjustment. The door must not move upwards or downwards when opening and closing, as this indicates that the vertical adjustment is incorrect.

The procedure for adjusting the door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Observe front door gap/shut lines.

Step 2. To be able to adjust gaps correctly, bolts -5-, -7-, -11- and -12- on the A-pillar must be loosened. For bolt -5-, the A-pillar lower trim must be removed.

Step 3. Other measures such as raising the door have no effect; subsequent pressure from above will cause the door to sack again.

Step 4. Bolts -4-, -6- and -13- and also guide bolts -2- and -8- must be loosened to correctly adjust the flush fitting of the door. Use door alignment tool -3320- with bit -3320/3- for this.

The procedure for adjusting the striker pin for the front door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. The following can be adjusted at the striker pin when the front door does not align with the rear door.

Step 2. Loosen striker pin -1- by unbolting bolts -2- on the B-pillar.

Step 3. Adjust the front door with the striker pin -1- so that the front door is flush with the rear door when shut (wind noise).

Maximum twist tolerance -A- of striker pin: ± 3°.

Step 4. Retighten bolts -2-. Specified torque: 20 Nm.

If the door outer panel has been removed before installing the door inner panel on the VOLKSWAGEN GOLF VARIANT 2007, the door inner part window frame must be adjusted to the roof frame, C-pillar, and front door.

The installation notes for bonding a new outer panel on the front door of the VOLKSWAGEN GOLF VARIANT 2007 are:

Note: If the front and rear door outer panels must be renewed, they must be done at the same time. When bonding-in both outer panels, the long fixing block from assembly tool set -T10237- is stuck on for the transition from the front outer panel to the rear outer panel.

If the door outer panel CDP coating is damaged on the inside in the area to be bonded or it has been painted, this area must be primed with glass/paint primer -D 009 200 02-.

The 1K glass adhesive -DH 009 100 01- must be heated in the cartridge heater -V.A.G 1939 A- for 20 minutes.

Adhesive -DA 004 600 A2- can be used for this procedure and is applied with the double cartridge gun -VAS 5237-; there is no requirement to preheat.

Clean contact surfaces on retaining rails thoroughly using cleaning solution -D 009 401 04-.

Apply adhesive material to appropriate surfaces at right angles to the retaining rail using cartridge gun -V.A.G 1628-.

Caution: The door outer panel must be installed within 10 minutes, or the adhesive properties of the adhesive will be impaired.

With assistance of both assembly blocks from assembly tool set -T10237-, place the door outer panel on the retaining rails and align with wedges and setting gauge -3371-, and press the contact surfaces of the assembly blocks onto the adjacent components.

Secure the door with fixing blocks from assembly tool set -T10237- during the curing period.

After installation, the door outer panel must align with other components, and gaps must be even.

If the adhesive bead is too thick and adhesive exudes between the retaining rail and the door outer panel, remove the excess adhesive.

The minimum curing period for door outer panels on the VOLKSWAGEN GOLF VARIANT 2007 is 180 minutes for 1K adhesive -DH 009 100 01- and 90 minutes for 2K adhesive -DA 004 600 A2-.

The minimum curing period is the time from bonding the outer panel on the door to the time the vehicle is taken into use or further work is carried out. During this time, the vehicle must stand on a level surface at room temperature (at least 15 °C).

Warning: The vehicle is safe to use only after the curing period is completed.

The specified torque for bolts is as follows when installing the door outer panel on the VOLKSWAGEN GOLF VARIANT 2007:

Bolt -2-: 10 Nm

Bolt -3-: 14 Nm

Bolt -4-: 10 Nm

The procedure for cleaning off excess adhesive sealing material from a front door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Use of adhesive remover -D 002 000 10- as a cleaning solution is recommended. Observe the appropriate safety precautions when performing this work.

Caution: When cleaning the vehicle, the door outer panel just bonded-in must not be moved.

Step 2. First clean the painted surface as much as possible using a dry cloth. Remove residual excess with adhesive remover -D 002 000 10-.

Step 3. Cleaning plastic trim: allow adhesive sealant to cure (approximately one hour) and then peel off.

To install the housing on the front door of the VOLKSWAGEN GOLF VARIANT 2007:

Step 1. Fit the housing -3- in the door handle -2- bearing bracket at right angles -arrow-.

The door handle -2- must rest only lightly against the door panel.

Step 2. Now tighten bolt -1- in the bearing bracket using socket wrench -T10072-.

The door handle -2- locates in the housing -3- with a well audible click.

Note: During installation, the housing must be pressed against the door panel. The door handle just rests lightly against the door panel.

Further installation is performed in reverse order of removal. Then always check the function while the door is still open, as an incorrectly fitted and adjusted Bowden cable cannot open the door.

The removal and installation sequence for the door handle on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is only for the right door handle. The removal and installation of the left door handle is similar.

The note regarding installing the door handle on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is: Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden cable to the door handle later.

The procedure for installing the door handle on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Swivel the door handle -1- into the door.

Step 2. Pull clip -2- in the panel opening and engage the clip in the door handle -1- -arrow-.

Note: Press the door handle -1- against the door panel when assembling. Clip -2- must engage audibly in the door handle -1-.

Step 3. Install the housing.

Then always check the function while the door is still open, as an incorrectly fitted and adjusted Bowden cable cannot open the door.

The removal and installation sequence for the bearing bracket on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is described only for the right bearing bracket. The removal and installation of the left bearing bracket is similar.

The removal and installation sequence for the door lock on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is only for the right door lock. The removal and installation of the left door lock is similar.

The specified torque for bolts when installing the door lock on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is 18 Nm.

Before closing the rear lid after installing the door lock on the VOLKSWAGEN GOLF VARIANT 2007 (saloon), always check the function of the lid release components.

The procedure for removing handle trim on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the rear lid trim.

Step 2. Remove the lock cylinder.

Step 3. Disconnect connector -5-.

Step 4. Remove nuts -6- and remove the handle trim -7-.

The specified torque for hexagon nuts when installing handle trim on the VOLKSWAGEN GOLF VARIANT 2007 is 8 Nm.

Before closing the rear lid after installing the handle trim on the VOLKSWAGEN GOLF VARIANT 2007, check the function of the lid release components.

The procedure for removing the lid lock on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the lock cover.

Step 2. Remove the rear lid trim.

Step 3. Disconnect connector -3- on the back of the lock.

Step 4. Remove bolts -2- and take off lock -1- from the rear lid.

The specified torque for hexagon nuts when installing the lid lock on the VOLKSWAGEN GOLF VARIANT 2007 is 8 Nm.

The note that applies to rear lid seals on the VOLKSWAGEN GOLF VARIANT 2007 is that if seals are removed, the sealant will spread to the inside of the seal and the flanks will be bent out slightly. If the seal is then refitted, a leak-free tight seal is not guaranteed. 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 the sides of the seal together before refitting.

The procedure for removing the rear lid seal on the VOLKSWAGEN GOLF VARIANT 2007 is to pull the rear lid seal -1- off the body flange -2-.

The installation procedure for the rear lid seal on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Align the rear lid seal -1- so that the vulcanised point -arrow- faces the centre of the left tail light.

Step 2. Push the seal -1- evenly onto the body flange -2-.

The special tools and workshop equipment required for the fuel tank flap unit (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Torque wrench -V.A.G 1783-

The specified torque for bolt -4- when removing and installing the tank flap unit (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is 1.5 Nm.

The procedure for removing the fuel tank flap unit (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Open the fuel tank flap.

Step 2. Remove the tank cap.

Step 3. Remove bolt -4-.

Step 4. Pull the rubber part of the tank flap unit -2- off the fuel tank filler neck -1-.

Step 5. Pull the tank flap unit -2- with the drain hose -3- to the rear and swing the fuel tank flap unit out of the side panel.

Step 6. Unclip the assembly part -5- out of the side panel and pull the assembly part off the release rod -7-.

Note: If the fuel tank filler flap does not open, it can be opened by hand using the release rod -7-. Remove the rear right luggage compartment trim for this.

The special tools and workshop equipment required for the fuel tank flap unit (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Torque wrench 5…50 Nm -V.A.G 1331-

The specified torque for bolt -4- when removing and installing the tank flap unit (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 is 1.5 Nm.

The special tools and workshop equipment required for the front door components on the VOLKSWAGEN GOLF VARIANT 2007 are:

Socket -T10072-

Assembly tool -T10118-

Door alignment tool -3320- with -3320/1- , -3320/2- and -3320/3-

Roller for door insulation foil -3356-

Torque wrench -V.A.G 1331-

Setting gauge -3371-

The materials required for door assembly on the VOLKSWAGEN GOLF VARIANT 2007 are:

1K or 2K glass adhesive -DH 009 100 01- or -DH 004 600 A2-

Glass primer/paint primer -D 009 200 02-

Cleaning solution -D 009 401 04-

Primer applicator -D 009 500 25-

Note: Observe curing period.

Note: Heat according to manufacturer’s instructions, using cartridge heater -V.A.G 1939 A-.

Note: Materials are stored in box -D 004 700-.

The caution regarding securing screws when joining the door inner part and outer panel on the VOLKSWAGEN GOLF VARIANT 2007 is: Different securing screws are used for the door outer panel. If these are fitted in the wrong positions, the outer panel for the door will be damaged.

The features of the bolts used to secure the door outer panel on the front door of the VOLKSWAGEN GOLF VARIANT 2007 are:

Bolt -3-: Feature is a bolt with a pointed end and thinner washer. Qty. 6 on the lower edge and Qty. 1 in the rear section of the door shoulder. Specified torque: 10 Nm.

Bolt -5-: Feature is a bolt with no pointed end and thicker washer. Qty. 10 for both retaining rails. Specified torque: 14 Nm.

Bolt -8-: Feature is a bolt with a pointed end and thicker washer. Qty. 1 in the area of the front section of the door shoulder. Specified torque: 10 Nm.

The procedure for adjusting the door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Observe the front door gap/shut lines.

Step 2. To be able to adjust gaps correctly, bolts -5-, -7-, -11- and -12- on the A-pillar must be loosened. For bolt -5-, the A-pillar lower trim must be removed.

Step 3. Other measures such as raising the door have no effect. Subsequent pressure from above will cause the door to sack again.

Step 4. Bolts -4-, -6- and -13- and also guide bolts -2- and -8- must be loosened to correctly adjust the flush fitting of the door. Use door alignment tool -3320- with bit -3320/3- for this.

Caution: The nut of the eccentric bolt -9- should not be loosened under any circumstances; it cannot be retightened using normal workshop tools.

Note: The door is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or does not stand proud, and all contours align when the door is closed. The vehicle must be standing on its wheels when adjustments are performed. If the door outer panel has been removed, the door inner part window frame must be adjusted to the roof frame, C-pillar, or rear door.

The procedure for adjusting the striker pin for the front door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. The following can be adjusted at the striker pin when the front door does not align with the rear door.

Step 2. Loosen striker pin -1- by unbolting bolts -2- on the B-pillar.

Step 3. Adjust the front door with the striker pin -1- so that the front door is flush with the rear door when shut (wind noise).

Maximum twist tolerance -A- of striker pin: ± 3°.

Step 4. Retighten bolts -2-. Specified torque: 20 Nm.

Warning: Only use this adjustment to adjust the door inwards or outwards; never use for vertical adjustment. The door must not move upwards or downwards when opening and closing. This indicates that the vertical adjustment is incorrect.

The procedure for removing the outer panel on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Prise out clips -3-, starting at the bottom of the door -1-, and remove cover -2-.

Step 2. Remove the lock cylinder.

Step 3. Remove the door handle.

Step 4. Remove bolt -1- from the bearing bracket -2- which is located behind the door outer panel.

Step 5. Remove all bolts -2-, -3- and -4-.

Step 6. Carefully remove the door outer panel.

The procedure for installing the outer panel on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Carefully position the outer panel on the door.

Step 2. Insert all bolts -2-, -3- and -4-.

Observe the correct usage for the different types of bolts:

Feature for bolt -2-: bolt with pointed end and thinner washer.

Feature for bolt -3-: bolt with no pointed end but with thicker washer.

Feature for bolt -4-: bolt with pointed end and thicker washer.

Step 3. Check whether the retaining rail guide pins are located in the appropriate guide holes in the inner part of the door. Only then tighten all bolts -2-, -3- and -4-.

Observe the correct specified torque for the different types of bolts.

Specified torque for bolt -2-: 10 Nm.

Specified torque for bolt -3-: 14 Nm.

Specified torque for bolt -4-: 10 Nm.

The installation notes for bonding a new outer panel on the front door of the VOLKSWAGEN GOLF VARIANT 2007 are:

Note: Observe installation notes in the chapter for bonding the new outer panel on the door.

The old (damaged) outer panel with retaining rails is removed.

Install the front -2- and rear -6- retaining rails on the inner part of the door -1-. Use the “bolt with no point but with thicker washer” for this.

Specified torque for bolts -3- and -5-: 14 Nm.

Fit two guide bolts -4- in the lower edge of the door inner part.

The painted outer panel for the door is first offered up without bonding agent.

Assembly blocks -3- from assembly tool set -T10237- are required when fitting the outer panel on the door. A strip of double-sided adhesive tape -6- is applied on the side with a cut-out step. The pin has the minimum dimension for the gap width. The surface with no adhesive tape is brought into position on the adjacent panel.

Stick the assembly block -3- on the outer panel -1- of the door.

Guide the outer panel -1- over the guide bolts on the lower edge of the door inner part.

Adjust the gap to the sill and height of the outer panel on the door using wedges -4- from the assembly tool set.

Lay the door outer panel -1- with assembly blocks on the adjacent panels -2- and -5-.

The minimum curing period for bonded outer panels on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is 180 minutes for 1K adhesive -DH 009 100 01- and 90 minutes for 2K adhesive -DA 004 600 A2-.

The minimum curing period is the time from bonding the outer panel on the door to the time the vehicle is taken into use or further work is carried out. During this time, the vehicle must stand on a level surface at room temperature (at least 15 °C).

Warning: The vehicle is safe to use only after the curing period is completed.

The procedure for cleaning off excess adhesive sealing material from the front door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Use of adhesive remover -D 002 000 10- as a cleaning solution is recommended. Observe the appropriate safety precautions when performing this work.

Step 2. First clean the painted surface as much as possible using a dry cloth. Remove residual excess with adhesive remover -D 002 000 10-.

Step 3. Cleaning plastic trim: allow adhesive sealant to cure (approximately one hour) and then peel off.

The procedure for removing and installing the door inner seal on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Pull the door inner seal off the body flange.

Installing:

Align the door inner seal so that the vulcanised point -arrow b- is located at the height of the lower hinge.

Start installing the door inner seal at the top radius -arrow a- of the door aperture.

Note: The removal and installation sequence is only for the right door inner seal. The removal and installation of the left door inner seal is similar.

The procedure for removing and installing the door outer seal on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Pull the door outer seal off the door.

Installing:

Step 1. Remove adhesive residues with the erasure disc of adhesive strip remover -VAS 6349-.

Step 2. Immediately before bonding the door outer seal, clean the bonding surface thoroughly with adhesive remover -D 002 000 10-.

Bonding surfaces must be free of dust and grease and there should be no adhesive residues.

Step 3. Align the door outer seal with the section -arrow b- towards the door lock securing bolts.

Step 4. The door outer seal vulcanised point -arrow c- should then be in the middle of the sill.

Step 5. Pull off the protective backing and start fitting the seal in the upper radius -arrow a- of the door. Do not pull the door outer seal excessively to avoid stretching the seal.

Step 6. Press the complete bonding surface of seal -3- onto the door -1- all around using roller -3356-.

To do this, push the seal aside -arrow a- so that the roller -3356- runs directly over the contact surface of the seal.

The roller can apply the necessary force -arrow b- to the bonding surface -2- only when the procedure described above is followed.

If the seal has stretched, cut the seal to the required length and press the butt joint well.

If seal -3- comes loose in small areas again, press the seal on well again using roller -3356-.

Note: The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen again.

Note: Removal and installation are described only for the right door outer seal. Removal and installation of the left door outer seal are similar.

The special tools and workshop equipment required for the rear door window (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Release tool -T10236-

Roller -T10314-

Torque wrench -V.A.G 1783-

The procedure for removing the door window for the rear door (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the rear door trim.

Step 2. Lower the door window until the spreader pin -3- and spreader plug -4- in the cut-out of the window regulator are accessible.

Note: If the work step cannot be carried out because there is a fault with the electric window motor, remove the motor to slide the window down.

Step 3. Screw a 5 mm bolt (approximately 70 mm long) into the spreader pin -3-.

Step 4. Pull the bolt and spreader pin out of the spreader plug -4-.

Step 5. Screw an 8 mm bolt (approximately 80 mm long) into the spreader plug -4-.

Note: Do not exert too great a pressure on the plug because otherwise the plug will fall into the door.

Step 6. Pull the spreader plug -4- out of the clamping jaws -2- and therefore out of the door window.

Step 7. Remove the window regulator motor.

Step 8. Lower the door window fully.

Step 9. Pull the window channel -3- out of the mounting.

Step 10. Remove screws -2- and pull the trim -1- towards the B-pillar in the direction of the arrow.

Step 11. Pull the door window upwards -arrow- out of the window slot.

The procedure for installing the door window for the rear door (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Note: When installing the door window, always renew the spreader plug and spreader pin. Before inserting the spreader plug and spreader pin, check the washer for damage.

Step 1. With the door window -1- removed, insert the spreader plug -3- in the middle – centralised.

Step 2. Press the spreader pin -2- flush into the spreader plug -3-.

Step 3. Remove the window slot seal (Item 1).

Step 4. Guide the door window -1- into the door and insert the door window into the mounting of the window regulator guide -4-.

Step 5. With light pressure from above -arrow-, engage the window -1- in the mounting of the window regulator guide -4-.

Step 6. Install the window slot seal (Item 1) again.

Further installation is performed in reverse order of removal. Carry out a functional test before installing the door trim.

The procedure for removing and installing the window regulator motor for the rear door window (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the door trim.

Step 2. Secure the door window against sliding down with adhesive tape.

Step 3. Release connectors -arrows- using a screwdriver in the direction of the arrow.

Step 4. Remove the three bolts -2-.

Step 5. Remove the window regulator motor with control unit -1- from the mounting plate.

Installing:

Step 1. Push the window regulator motor -1- into place and reconnect the connector -arrows-.

Step 2. Move the door window lightly up and down so that the splines between the motor and the cable drum engage easier.

Step 3. Tighten bolts -2- window regulator motor. Specified torque: 3.5 Nm.

Step 4. Run the window regulator twice in each direction to the upper and lower stops. This initiates and readies the window regulator motor and activates the roll-back function.

Note: The removal and installation sequence is only for the right window regulator motor. The removal and installation of the left window regulator motor is similar.

The special tools and workshop equipment required for the rear door window (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Roller -T10314-

Torque wrench -V.A.G 1783-

The procedure for removing the door window for the rear door (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the rear door trim.

Step 2. Lower the door window completely.

Step 3. Pull the window channel -3- out of the mounting.

Step 4. Remove screws -2- and pull the trim -1- towards the B-pillar in the direction of the arrow.

Step 5. Lever out cap -5-.

Step 6. Lift the door window until the spreader pin -3- and spreader plug -4- in the cut-out of the window regulator are accessible.

Note: If the procedure cannot be carried out because there is a fault with the electric window regulator, remove the electric window motor to slide the window down.

Step 7. Screw a 5 mm bolt (approximately 70 mm long) into the spreader pin -3-.

Step 8. Pull the bolt and spreader pin out of the spreader plug -4-.

Step 9. Screw an 8 mm bolt (approximately 80 mm long) into the spreader plug -4-.

Note: Do not exert too great a pressure on the plug because otherwise the plug will fall into the door.

Step 10. Pull the spreader plug -4- out of the clamping jaws -2- and therefore out of the door window.

Step 11. Remove the window regulator motor.

Step 12. Lower the door window fully.

Step 13. Pull the window slot inner seal -6- off the door inner panel.

The procedure for installing the door window for the rear door (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Note: When installing the door window, always renew the spreader plug and spreader pin. Before inserting the spreader plug and spreader pin, check the washer for damage.

Step 1. With the door window -1- removed, insert the spreader plug -3- in the middle – centralised.

Step 2. Press the spreader pin -2- flush into the spreader plug -3-.

Step 3. Remove the window slot seal (Item 1).

Step 4. Guide the door window -1- into the door and insert the door window into the mounting of the window regulator guide -4-.

Step 5. With light pressure from above -arrow-, engage the window -1- in the mounting of the window regulator guide -4-.

Step 6. Install the window slot seal (Item 1) again.

Further installation is performed in reverse order of removal. Carry out a functional test before installing the door trim.

The procedure for removing and installing the window regulator motor for the rear door window (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the door trim.

Step 2. Secure the door window against sliding down with adhesive tape.

Step 3. Pull connector -1- in the direction of the arrow off the window regulator motor with control unit -3-.

Step 4. Remove the three bolts -2-.

Step 5. Remove the window regulator motor with control unit -3- from the assembly carrier.

Installing:

Step 1. Install the window regulator motor with control unit -3-.

Step 2. Move the door window lightly up and down so that the splines between the motor and the cable drum engage easier.

Step 3. Tighten bolts -2- for the window regulator motor. Specified torque for bolts -2-: 3.5 Nm.

Step 4. Run the window regulator twice in each direction to the upper and lower stops. This initiates and readies the window regulator motor and activates the roll-back function.

Note: The removal and installation sequence is only for the right window regulator motor. The removal and installation of the left window regulator motor is similar.

The special tools and workshop equipment required for the sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Roller for door insulation foil -3356-

Front end hook -3370-

Torque wrench -V.A.G 1783-

Removal wedge -3409-

The warning when removing the sliding/tilting sunroof glass panel on the VOLKSWAGEN GOLF VARIANT 2007 is: The guide plate must not be moved to the “Open” position when removed, because the water channel will not be compressed by the glass panel and can become wedged together in the roof.

For the zero position when installing the sliding/tilting sunroof glass panel on the VOLKSWAGEN GOLF VARIANT 2007, the panel must be installed in the zero position (panel closed). The mark -arrow- on the rear of the guide upper section -1- must, on both sides, lie within the marks dimension -a- on the guide plate -2-. The guide plate -2- must be located in the guide rails (cannot be moved by hand).

The procedure for adjusting the height of the sliding/tilting sunroof glass panel on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the bellows.

Step 2. Loosen the sliding/tilting sunroof glass panel -2- securing bolts -1- on the left and right (do not remove).

Step 3. Run the sliding/tilting sunroof glass panel to the “open” position.

Step 4. Run the sliding/tilting sunroof glass panel to the “closed” position.

Step 5. Carry out height adjustment of the sliding/tilting sunroof glass panel at the front and rear on both sides as follows:

Front panel adjustment:

-a- = 0…1 mm lower than roof.

-Arrow- points forwards.

Tighten the foremost left and right bolts (5 Nm).

Rear panel adjustment:

-b- = 0…1 mm higher than roof.

-Arrow- = Forwards.

First tighten the middle and then the rear bolts on the left and right (5 Nm).

Note: To achieve the best possible optical appearance, ensure that adjustments on the left and right are as uniform (symmetric) as possible. The glass panel should not be higher than the roof at any point at the front or lower than the roof at any point at the rear.

Step 6. Install the bellows.

Note: After adjusting the panel height, tighten the securing screws (5 Nm). Install the bellows after adjusting the height of the panel.

Note: The glass panel height adjustment is performed after the glass panel has been closed from the tilt position. Sliding/tilting sunroof glass panel 0 (zero) position OK (checking).

The note about adjusting the panel seal on the VOLKSWAGEN GOLF VARIANT 2007 is: If the pressure is too little, the roof seal -2- can be pushed apart with the removal wedge -3409- -1-.

The procedure for removing and installing the wind deflector on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Fully open the sliding/tilting sunroof glass panel.

Step 2. Push the wind deflector and height limit stop out of the front of the roof aperture and set the wind deflector vertical.

Step 3. Insert the front-end hook -3370- between the edge of the roof and the wind deflector bearing -arrow-.

Step 4. Pull the wind deflector bearings out of the detents on the left and right, in the direction of the arrow, using the front-end hook -3370-.

Step 5. Remove the wind deflector upwards out of the guide rails.

Installing:

Step 1. Place the wind deflector in the guide rails and slide the wind deflector with the height limit stop under the front of the roof aperture on both sides.

Step 2. Using light pressure, press the wind deflector bearings into the guide rails.

Note: The wind deflector mounting bracket must engage audibly in the guide rails. The securing clip of the mounting bracket must always be renewed after removal.

The requirements for removing and installing the sliding/tilting sunroof glass panel drive on the VOLKSWAGEN GOLF VARIANT 2007 are:

Engine not running and ignition off, key not in ignition, and door open.

Switch off the engine and ignition, withdraw the key, and open the door. This condition must remain until the drive has been installed.

Caution: Remove or install the drive for the tilting/sliding sunroof glass panel only when the sunroof is closed (0 position).

The procedure for installing the sliding/tilting sunroof glass panel drive on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the screws -arrows- and pull off the sliding/tilting sunroof drive.

Step 2. Separate the connector for the sliding/tilting sunroof drive.

Step 3. The screws for the sliding/tilting sunroof drive are microencapsulated and must always be renewed (3.5 Nm).

Step 4. Install in reverse order of removal.

Step 5. After installation is complete, the key can be inserted into the lock cylinder of the ignition/starter switch again.

Step 6. Finally carry out a functional check.

The procedure for checking parallel running for the sliding/tilting sunroof glass panel on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the sliding/tilting sunroof glass panel drive.

Step 2. The mark -arrow- on the rear of the guide upper section -1- must, on both sides, lie within the marks dimension -a- on the guide plate -2-.

The guide plate -2- must be located in the guide rails (cannot be moved by hand).

Step 3. If this is not the case, adjust parallel running.

Step 4. Push the guide upper part -1- both sides centrally between the marks.

Step 5. Install the drive in this position (zero position).

Step 6. Then check the zero position.

The procedure for removing and installing the assembly frame for the panorama sliding sunroof on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the moulded headliner.

Step 2. Vehicles with net partition: Remove the net partition mounting.

Step 3. All vehicles: Remove the grab handle mounting (roof).

Step 4. Pull off the water drain hoses from the connections -arrows- of the assembly frame -1-.

Step 5. Disconnect the connector to the wiring harness of the sliding sunroof motor -8-.

Step 6. Unscrew bolts -3- and -4- of the console -5- and remove the left and right consoles.

Step 7. Unscrew bolts -2- on the assembly frame -1- and remove the assembly frame from the vehicle with the help of at least one mechanic.

Installing:

Step 1. Lift the assembly frame -1- into the vehicle with the help of at least a second mechanic.

Step 2. When screwing, align the assembly frame using 2 cylindrical pins (shank end of drill ∅ 10mm) in the elongated holes -6- and -7-.

Step 3. Screw bolts -2- in, but do not tighten.

Step 4. Tighten bolts -3-, specified torque: 8 Nm.

Step 5. Tighten bolts -4-, specified torque: 4.5 Nm.

The procedure for removing the rear part of the panorama sliding sunroof assembly frame on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the assembly frame from the vehicle.

Step 2. Pull off the water drain hoses from the connections -arrows- of the assembly frame -1-.

Step 3. Separate connector -3- on the sliding/tilting sunroof glass panel drive -4-.

Step 4. Remove bolts -2- and remove the carrier unit -1- from the vehicle with the help of a second mechanic.

The procedure for installing the rear part of the panorama sliding sunroof assembly frame on the VOLKSWAGEN GOLF VARIANT 2007 is:

Caution: Carry out the following sequences using extreme care so as not to damage the moulded headliner.

Step 1. Fit the carrier unit -1- into the roof aperture with the help of a second mechanic.

Step 2. During installation, align the carrier unit -1- in the roof using two cylindrical pins (shank end of drill) 12 mm front right and 10 mm rear left.

Step 3. Install bolts -2-.

Step 4. Check the routing of the wiring and connectors of the electrical consumers in the roof and correct as necessary.

Step 5. Tighten the screws (8 Nm) for the carrier unit -1-, starting at the sunroof drive -4- and moving rearward, alternating between the left and right sides.

Step 6. Install the water drain hoses -arrows-.

Step 7. Attach connector -3- on the sliding/tilting sunroof glass panel drive -4-.

Step 8. Install the moulded headliner.

The procedure for operating the panorama sliding sunroof without current on the VOLKSWAGEN GOLF VARIANT 2007 is:

Note: In the event of power failure, the sliding/tilting sunroof with glass panel can be moved by hand using a hexagon key directly on the drive. The hexagon key is located in the vehicle tool kit.

Step 1. Remove the lights and front operating unit.

Step 2. Guide the hexagon key into the bolt on the drive.

Step 3. Press the key upwards -arrow- to release the drive.

The bolt will be pressed a few millimetres inwards -a-. The sliding/tilting sunroof glass panel can only be moved in this position.

The procedure for removing and installing the guide plate on the sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the glass panel for the sunroof.

Step 2. Using a screwdriver, unclip spacer -2- from the guide plate -1- at the front and rear -arrows-.

Step 3. Pull the spacer -2- in the direction of the arrow out of the guide plate -1-.

Step 4. Lift the guide plate up -1- in the direction of the arrow.

Step 5. Slide the front guide -2- forwards and pull the guide plate -1- in the direction of the arrow out of the front guide -2-.

Note: Always renew guides with cables as a pair.

Step 6. Remove the carrier unit.

Step 7. Remove the guide plate.

Step 8. Detach the water channels -1- carefully using a screwdriver on both sides on the guide locating hook -2- in the direction of the arrow and remove the water channels.

Step 9. Release the end piece upper part -1- fastening -arrows- from the end piece lower part -2- and pull off upwards.

Installing:

Install in reverse order of removal.

The procedure for cleaning the water drain hoses for the panorama sliding sunroof on the VOLKSWAGEN GOLF VARIANT 2007 is:

Front water drain hoses:

The front water drain hoses run through the A-pillars and end at the bulkhead cross member. Cleaning is done from the panorama sliding roof cut-out.

Rear water drain hoses:

The rear water drain hoses run through the D-pillars and end in the rear wheel housings. Cleaning is done from the wheel housing. The wheel housing liner must be removed.

Note: For cleaning, a locally manufactured tool made from a speedometer inner cable, approximately 2300 mm long is recommended.

The specified torque for bolts when removing and installing the front bumper cover on the VOLKSWAGEN GOLF VARIANT 2007 is as follows:

Bolt -1-: 2 Nm

Bolt -2-: 3.5 Nm

Bolt -4-: 2 Nm (Qty. 3 on each side)

Bolt -5-: 2 Nm (Qty. 6)

Bolt -6-: 3.5 Nm (Qty. 2)

The note regarding the removal and installation procedures for the front bumper cover on the VOLKSWAGEN GOLF VARIANT 2007 is that they may have to be modified slightly depending on variations in equipment.

The procedure for removing the front bumper cover on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the radiator grille.

Step 2. For vehicles with headlight washer system, pull the washer jet with the cover cap up out of the bumper cover onto the stop and unclip the cover cap.

Step 3. Remove bolts -2-.

Step 4. Remove bolts -5- from below.

Step 5. Remove bolts -4- and -1- (point upwards) on the left and right in the area of the wheel housing liner.

Further dismantling requires the help of a second mechanic.

Step 6. With the help of a second mechanic, pull the front bumper cover -3- parallel off the vehicle.

Step 7. Disconnect electrical connectors from all electrical components (if fitted).

The procedure for installing the front bumper cover on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. With the help of a second mechanic, install the front bumper cover -1- on the lock carrier ensuring it remains parallel with the vehicle.

Note: When positioning the front bumper cover -1-, ensure it is parallel to the wing.

Step 2. Ensure joints are parallel and shut lines are equal.

Step 3. Start bolts -2, 3, 4, 5 and 6- and tighten these to the relevant torque settings.

Further installation is performed in reverse order of removal.

The features of the bolts used to secure the outer panel of the front bumper cover on the VOLKSWAGEN GOLF VARIANT 2007 (Cup Edition) are:

Bolt -2-: Specified torque: 2 Nm. Points upwards.

Bolt -3-: Qty. 4 on each side. Specified torque: 2 Nm.

Bolt -4-: Left and right. Specified torque: 3.5 Nm.

Bolt -5-: Qty. 6. Specified torque: 2 Nm.

Bolt -6-: Qty. 2. Specified torque: 3.5 Nm.

The parts in the assembly overview – rear bumper cover (saloon) for the VOLKSWAGEN GOLF VARIANT 2007 are:

Bolt -1-: Qty. 1 on each side. Specified torque: 8 Nm.

Bolt -2-: Specified torque: 5 Nm.

Spreader rivet -3-: Left and right.

Bolt -4-: Qty. 3. Only on right side. Specified torque: 2 Nm.

Bolt -5-: Qty. 3. Specified torque: 5 Nm.

Bumper cover -6-: Material PP/EPDM.

Bolt -7-: Qty. 3 on each side. Specified torque: 2 Nm.

Quick-release screw -9-: Qty. 3.

The procedure for removing the rear bumper cover (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the tail lights in the left and right side panels.

Step 2. Remove bolts -7- on the left and right in the area of the wheel housing liner.

Step 3. Lever out the spreader rivet -3- on the left and right using a screwdriver.

Step 4. From below, remove bolts -4- and -5-.

Step 5. Remove bolts -2- from above.

Step 6. Remove bolt -1- on the left and right in the luggage compartment.

Further dismantling requires the assistance of a second person.

Step 7. With the help of a second mechanic, pull the rear bumper cover -6- parallel out of the guide profiles.

Step 8. Disconnect connectors from all electrical components.

The procedure for installing the rear bumper cover (saloon) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. With the help of a second mechanic, guide the rear bumper cover parallel into the left and right guides.

Note: Ensure when fitting the rear bumper cover that it runs parallel along the left and right guide profiles.

Step 2. Install the left and right spreader rivets -3-.

Step 3. Ensure that joints are parallel and specified dimensions are maintained.

Step 4. Start bolts -1, 2, 4, 5 and 7- and tighten these to the relevant torque settings.

Step 5. Install the diffuser -8- and lock the quick-release screws -9-.

Further installation is performed in reverse order of removal.

The specified torques for bolts when installing the rear bumper cover (saloon, Cup Edition) on the VOLKSWAGEN GOLF VARIANT 2007 are:

Bolt -1-: 5 Nm

Bolt -4-: 2 Nm

Bolt -5-: 2 Nm

The procedure for removing the rear bumper cover (saloon, Cup Edition) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the luggage compartment side trim.

Step 2. Remove the tail lights in the left and right side panels.

Step 3. Release the quick-release screw -9- and remove the diffuser -8- from the spoiler.

Step 4. Remove bolts -7- on the left and right in the area of the wheel housing liner.

Step 5. Lever out the spreader rivet -3- on the left and right using a screwdriver.

Step 6. From below, remove bolts -4- and -5-.

Step 7. Remove bolts -2- on the left and right from above.

Step 8. Remove bolt -1- on the left and right in the luggage compartment.

Further dismantling requires the assistance of a second person.

Step 9. With the help of a second mechanic, pull the rear bumper cover -6- parallel out of the guide profiles.

Step 10. Disconnect connectors from all electrical components.

The special tools and workshop equipment required for the flush bonded windows on the VOLKSWAGEN GOLF VARIANT 2007 are:

Removal kit for flush bonded windows -V.A.G 1474 A-

Suction lifter -V.A.G 1344-

Cutting tool -V.A.G 1351-

Windscreen removal kit -V.A.G 1755-

Cartridge gun -V.A.G 1628-

Cartridge heater -V.A.G 1939 A-

Electric cutter -V.A.G 1561 A-

Cutting blade -V.A.G 1561/2-

Scraping blade -V.A.G 1561/8-

Cutter (offset) -V.A.G 1561/10-

Cutting blade -V.A.G 1561/19-

Double cartridge gun -VAS 5237-

Removal wedge -T10039/1-

The materials required for flush bonded windows on the VOLKSWAGEN GOLF VARIANT 2007 are:

2K glass adhesive -DA 004 600 A2-

1K glass adhesive -DH 009 100 03-

Activator -D 181 801 A1-

Glass primer/paint primer -D 009 200 02-

Cleaning solution -D 009 401 04-

Primer applicator -D 009 500 25-

Adhesive remover -D 002 000 10-

Cutting cord -357 853 999-

Note: Observe curing period. Double cartridge gun -VAS 5237- must be used to apply these materials. Small cartridge, 110 ml, for sealing and/or when a 400 ml cartridge alone is not sufficient. Heat according to manufacturer’s instructions, using cartridge heater -V.A.G 1939 A-. Materials are stored in box -D 004 700-.

The procedure for removing the windscreen on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the plenum chamber cover.

Step 2. Remove the A-pillar trim.

Step 3. Remove the sun visor.

Step 4. Remove the interior mirror.

Step 5. Remove the moulded headliner.

Step 6. Slide cover -V.A.G 1474/8- between the windscreen -1- and the dash panel.

Step 7. Thrust awl -V.A.G 1474/2- -2- through the adhesive bead.

Step 8. Pull the cutting cord -3- through the adhesive sealing material into the inside of the vehicle using awl -V.A.G 1474/2- -2-.

Step 9. Secure the inside end of the cutting cord against falling out using pull handle -V.A.G 1351/1- -3-.

Step 10. Place the cutting cord -2- using a small tube -1- in the upper area of the window.

Step 11. Lay the cutting cord -2- around the window and guide the second end of the cord inwards into the interior. Ensure that the cutting cord -2- lies under the window in the corners.

Step 12. Secure the other end of the cord to the reel device -V.A.G 1654-.

Step 13. Position the reel device -V.A.G 1654- in “position I”.

Step 14. Reposition the reel device -V.A.G 1654- as necessary and cut the window free.

Step 15. Use wedge -V.A.G 1474/5- to press the cutting cord against the window glass while cutting in order to avoid damaging the dash panel and to create clearance at the window flange.

The procedure for installing the windscreen on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Preparing used undamaged window for glazing.

Step 2. Preparing new window for glazing.

Step 3. Preparing the body flange for glazing.

Step 4. Installation instructions.

Step 5. Minimum curing period.

Step 6. Apply adhesive material to the primed area -1- or to the trimmed sealant bead, holding the double cartridge gun -VAS 5237- at a right angle to the window.

Warning: The window must be installed within 10 minutes, or the adhesive properties of the glass adhesive will be impaired.

Step 7. Using two suction lifters -V.A.G 1344- , install the glass pane in the window aperture, align to the centre, and press onto the spacing lip.

Step 8. Secure the windscreen during the curing period with window adjusters.

Step 9. It is absolutely necessary to install the plenum chamber cover as described.

Step 10. Replace stickers (e.g. for airbag) which may be installed.

Step 11. The activator must not come into contact with the window heater bus bar.

Step 12. If the adhesive bead is too thick and the adhesive expands onto the area of the window heating, remove the excess adhesive.

The minimum curing period for 2K adhesive -DA 004 600 A2- when installing bonded windows on the VOLKSWAGEN GOLF VARIANT 2007 is three hours for all windows.

The minimum curing period is the time from bonding the window until the vehicle may be used. During this time, the vehicle must stand on a level surface at room temperature (at least 15 °C).

Warning: The vehicle is safe to use only after the curing period is completed.

The procedure for cleaning off excess adhesive sealing material after installing flush bonded windows on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Use of adhesive remover -D 002 000 10- as a cleaning solution is recommended. Observe the appropriate safety precautions when performing this work.

Warning: When cleaning freshly installed glass from the inside in the vehicle, do not press the glass outwards.

Step 2. First clean the painted surface as much as possible using a dry cloth. Remove residual excess with adhesive remover -D 002 000 10-.

Step 3. Cleaning plastic trim: allow the adhesive sealant to cure (approximately one hour) and then peel off.

The procedure for removing the door window for the front door on the VOLKSWAGEN GOLF VARIANT 2007 is:

Note: The bolt -3- is accessible from the interior and exterior. From the exterior, the bolt has a right-hand thread. This means: from the exterior, the bolt is removed by turning it to the left; from the interior, the bolt is removed by turning it to the right.

Step 1. Remove the front door trim.

Step 2. Lever out caps -4-.

Step 3. Lower the door window -1- until the clamping bolts -3- for mounting -2- are accessible.

Note: If the work step cannot be carried out because there is a fault with the electric window motor, remove the motor to slide the window down.

Caution: Remove bolt -3- from the interior by turning it clockwise.

Step 4. Loosen bolts -3- (do not remove) from the inside by turning to the right and press the clamping jaws apart.

Step 5. Lift the rear of the door window -1- and swivel it out of the door forwards, in the direction of the arrow.

The specified torque for the bolt when installing the door window on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is 8 Nm.

The procedure for adjusting the door window on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove the front door trim.

Step 2. Lever out caps -4-.

Step 3. Lower the door window -1- until the clamping bolts -3- for mounting -2- are accessible.

Caution: Remove bolt -3- from the interior by turning it clockwise.

Step 4. Loosen bolts -3- (do not remove) from the inside by turning to the right and press the clamping jaws apart.

Step 5. Applying light pressure, press the door window -1- in the clamping jaws in the direction of the arrow and align the door window tension-free at the rear window channel. When doing so, ensure that the door window -1- is positioned parallel to the window channel.

Step 6. Tighten the clamping jaws by turning the bolts anti-clockwise from the interior. Specified torque for the bolt: 8 Nm.

Step 7. Test for proper function.

Further installation is performed in reverse order of removal.

The specified torque for bolts -2- for the window regulator motor on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is 3.5 Nm.

After installing the window regulator motor on the front door of the VOLKSWAGEN GOLF VARIANT 2007:

Run the window regulator twice in each direction to the upper and lower stops. This initiates and readies the window regulator motor and activates the roll-back function.

The procedure for removing the window channel trim strip on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Push the window channel -1- in the top rear area slightly to the side.

Step 2. Remove the spreader rivet -6- for the window channel -1-.

Step 3. Pull the trim strip -5- out of the window channel -1- in the direction of the arrow.

Trim -2- must not be removed.

The procedure for installing the window channel trim strip on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Spray the window channel with soapy water.

Step 2. Press the trim strip -1- evenly -arrow- into the window channel -2- by hand.

Step 3. Then press the window channel -2- fully into the mounting of the trim strip with roller -T 10314-.

Further installation is performed in reverse order of removal.

The procedure for removing and installing the window regulator on the front door of the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the door outer panel.

Step 2. Remove the door window.

Step 3. Remove bolts -2- from the mounting plate -3-.

Step 4. Remove bolts -5- for the window regulator.

Step 5. Remove the window regulator -1- with drive -4- and mounting plate -3- for the window regulator motor from the inner part of the door.

Installing:

Install in reverse order of removal.

Carry out a functional check before installing the door outer panel.

The procedure for removing and installing the door window for the rear door (Variant) on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the rear door trim.

Step 2. Lower the door window completely.

Step 3. Pull the window channel -3- out of the mounting.

Step 4. Remove screws -2- and pull the trim -1- towards the B-pillar in the direction of the arrow.

Step 5. Lever out cap -5-.

Step 6. Lift the door window until the spreader pin -3- and spreader plug -4- in the cut-out of the window regulator are accessible.

Note: If the procedure cannot be carried out because there is a fault with the electric window regulator, remove the electric window motor to slide the window down.

Step 7. Screw a 5 mm bolt (approximately 70 mm long) into the spreader pin -3-.

Step 8. Pull the bolt and spreader pin out of the spreader plug -4-.

Step 9. Screw an 8 mm bolt (approximately 80 mm long) into the spreader plug -4-.

Note: Do not exert too great a pressure on the plug because otherwise the plug will fall into the door.

Step 10. Pull the spreader plug -4- out of the clamping jaws -2- and therefore out of the door window.

Step 11. Remove the window regulator motor.

Step 12. Lower the door window fully.

Step 13. Pull the window slot inner seal -6- off the door inner panel.

Installing:

Step 1. With the door window -1- removed, insert the spreader plug -3- in the middle – centralised.

Step 2. Press the spreader pin -2- flush into the spreader plug -3-.

Step 3. Guide the door window -1- into the door and insert the door window into the mounting of the window regulator guide -4-.

Step 4. With light pressure from above -arrow-, engage the window -1- in the mounting of the window regulator guide -4-.

Step 5. Further installation is performed in reverse order of removal. Carry out a functional test before installing the door trim.

Note: When installing the door window, always renew the spreader plug and spreader pin. Before inserting the spreader plug and spreader pin, check the washer for damage.

The procedure for removing and installing the window channel trim strip on the rear door window (saloon) of the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Push the window channel -2- in the top front area slightly to the side.

Step 2. Remove the spreader rivet -5- for the window channel trim strip -1-.

Step 3. Pull the trim strip -1- out of the window channel -2- in the direction of the arrow.

Installing:

Step 1. Spray the window channel with soapy water.

Step 2. Press the trim strip -1- evenly -arrow- into the window channel -2- by hand.

Step 3. Then press the window channel -2- fully into the mounting of the trim strip with roller -T 10314-.

Further installation is performed in reverse order of removal.

Note: To prevent wind noise, ensure the window channel seats evenly when installing.

The special tools and workshop equipment required for the roof railing on the VOLKSWAGEN GOLF VARIANT 2007 are:

Torque wrench 5…50 Nm -V.A.G 1331-

Plastic wedge -T10039/1-

The procedure for removing the roof railing on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Using wedge -T10039/1- , lever out the front and rear roof railing covers -1- in the direction of the arrow.

Step 2. Lever the front and rear covers of the roof railing -1- in the direction of arrow A- and press them in the direction of arrow B-.

Step 3. Pull out the cover for the roof railing -1-.

Step 4. Remove bolt -3- from the front and rear roof railing mounting -2- (20 Nm).

Step 5. Pull the middle cover -1- off the roof railing -3- in the direction of the arrow.

Step 6. Remove bolt -2- from the middle roof railing mounting -3- (20 Nm).

The procedure for installing the roof railing on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Install in reverse order of removal.

Step 2. Check the roof railing covers for damage and replace as necessary.

The special tools and workshop equipment required for the radiator grille on the VOLKSWAGEN GOLF VARIANT 2007 are:

Torque wrench -V.A.G 1783-

Torque wrench -V.A.G 1332-

The assembly overview for the radiator grille on the VOLKSWAGEN GOLF VARIANT 2007 includes:

Radiator grille -1- (Removing, Installing)

Bolt -2-: Qty. 4. Specified torque: 2 Nm.

VW emblem -3- (Clipped into radiator grille. Removing, Installing).

The procedure for removing the radiator grille on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove bolts -2-.

Step 2. Release clips -arrows- from the lock carrier using a small screwdriver.

Step 3. Tilt the radiator grille -1- forwards slightly and pull it upwards out of the bumper cover.

The procedure for installing the radiator grille on the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Insert the radiator grille -1- into the bumper cover mounting from above and tilted forwards slightly.

Step 2. Tilt the radiator grille -1- towards the lock carrier and locate the clips -arrows- in the lock carrier.

Step 3. Install bolts -2- (2 Nm).

The special tools and workshop equipment required for mouldings and trims on the VOLKSWAGEN GOLF VARIANT 2007 are:

Torque wrench -V.A.G 1783-

Double cartridge gun -VAS 5237-

Hot air blower -V.A.G 1416-

Removal wedge -3409-

The procedure for removing side panel trim strips on GLI vehicles for the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Remove bolts -1- (Torx T25) from the body.

Step 2. Remove the side panel trim strip -2- in the direction of the arrow.

As necessary:

Slide the retainer -2- forwards and release it as described -arrow-.

Remove damaged bolts -1-.

Note: The part number for bolts -1- deviates from the production number. Refer to the parts department.

The procedure for installing side panel trim strips on GLI vehicles for the VOLKSWAGEN GOLF VARIANT 2007 is:

Step 1. Clean the side panel and retainer to remove adhesive remains. Isopropyl alcohol is recommended.

As necessary:

Install bolts -1-. Specified torque: 1.2 ±0.1 Nm.

Install the retainer -2-, by checking that all bolts fit in their respective holes then slide the retainer forwards.

Continuation for all cases.

The safety requirements when removing special add-on parts on the VOLKSWAGEN GOLF VARIANT 2007 are:

Caution: When removing special add-on parts, use suitable gloves and protective eyewear.

Special add-on parts must cure at least 3 hours after being bonded before work on the vehicle is continued.

The minimum curing period for newly bonded attaching parts on the VOLKSWAGEN GOLF VARIANT 2007 is 3 hours.

The minimum curing time is the time from bonding the add-on parts until the vehicle may be used. During this time, the vehicle must stand on a level surface at room temperature (at least 15 °C).

Warning: The vehicle is safe to use only after the curing period is completed.

The procedure for preparing a new add-on part for bonding on the VOLKSWAGEN GOLF VARIANT 2007 is:

Warning: Mask off primed and bonding surfaces properly before painting.

Step 1. Immediately before bonding add-on parts, clean the bonding surface thoroughly with adhesive remover -D 002 000 10-.

Bonding surfaces must be free of dust and grease and there should be no adhesive residues.

Step 2. Now apply plastic primer -D 009 600- using applicator -D 009 500 25- equally in one stroke.

Drying time approximately 10 minutes.

The body component must be prepared for bonding.

Step 3. A thin coat of 2K glass adhesive -DA 004 600 A2- must be applied evenly to the primed surfaces of the add-on parts with the double cartridge gun -VAS 5237-.

The procedure for installation instructions for body kit parts on the VOLKSWAGEN GOLF VARIANT 2007 is:

The surfaces to be primed for the body kit parts should be completely clean.

Step 1. Remove adhesive residue using adhesive remover -D 002 000 10-.

Step 2. Soak a cloth in silicon remover -LSE 020 100 A3-.

Step 3. Clean the area of application for the adhesive bead twice thoroughly using a cloth soaked with the solution and allow to dry.

Step 4. Now apply glass/paint primer using applicator -D 009 500 25- evenly in one stroke.

Drying time approximately 10 minutes.

Adhesive sealant must be applied to the primed areas of the add-on parts.

Warning: Body kit parts should be installed within 10 minutes, or the bonding properties of the adhesive will be impaired.

Gap dimensions should be kept to an absolute minimum, up to approximately 1 mm.

Use adhesive tape to secure add-on parts in position during the minimum curing time.

The procedure for renewing the scuff protection film on the VOLKSWAGEN GOLF VARIANT 2007 is:

Removing:

Step 1. Remove the inner seal for the front door in the area of the side member.

Step 2. Heat the front scuff protection film -1- using a hot air blower -V.A.G 1416- and pull the scuff protection film -1- from the sill.

Installing:

Step 1. Clean the installation area with adhesive remover -D 002 00 10-.

Step 2. Pull off the protective backing -2-.

Step 3. Position the front scuff protection film -1- on the reference points -a- = 155 mm and press it smooth using a plastic blade wrapped in a soft paper towel.

Note: Renewing scuff protection films is described only for the left side. The right side is similar.

The installation instructions for lettering and emblems on the VOLKSWAGEN GOLF VARIANT 2007 are:

Note: Before removal, heat the lettering or emblem with a hot air blower -V.A.G 1416-.

If the lettering or emblem is installed for the first time on a new vehicle and newly painted surfaces, the procedure in Workshop manual “Paint”; “Paintwork repairs”; “Paint finish”; “Mouldings & Film” should be observed.

If the lettering or emblem is removed and reinstalled, only use adhesive remover -D 002 000 10- to remove the adhesive remains.

Ensure that bonding surfaces are free of dust and grease.

Bond the lettering or emblem immediately after cleaning.

Pull the protective backing off only directly prior to installation.

The working temperature is approximately 21 °C.

The rear lettering dimensions (saloon) for the VOLKSWAGEN GOLF VARIANT 2007 are:

Dimension -a- = 25 mm. From the outer edge of the rear lid to the lettering.

Dimension -b- = 15 mm. From the lower edge of the tail light aperture in the rear lid to the upper edge of the lettering.

The rear lettering dimensions (Golf Variant) for the VOLKSWAGEN GOLF VARIANT 2007 are:

Dimension -a- = 5 mm. Lower edge of lettering to height of lower edge of rear light -1-.

Transfer -dimension a- from the outer edge of the rear lid to the lettering.

The rear lettering dimensions (Jetta Variant) for the VOLKSWAGEN GOLF VARIANT 2007 are:

Dimension -a- = 25 mm.

Transfer -dimension a- from the outer edge of the rear lid to the lettering.

Lower edge of lettering to the height of the upper edge of the rear light -1-.

The dimensions for the emblem on the left wing for the VOLKSWAGEN GOLF VARIANT 2007 (Individual) are:

Dimension -a- = 551 mm. Transfer -dimension a- from the lower edge of the wing to the wing.

Dimension -b- = 14 mm. Transfer -dimension b- from the end point of dimension a to the corner of the emblem.

Dimension -c- = 70 mm. Use -dimension c- to check the distance from the upper edge of the emblem to the edge of the wing.

Dimension -d- = 92 mm. Use -dimension d- to check the distance from the lower edge of the emblem to the edge of the wing.

The dimensions for the emblem on the right wing for the VOLKSWAGEN GOLF VARIANT 2007 are:

Dimension -a- = 550 mm. Transfer -dimension a- from the lower edge of the wing to the wing.

Dimension -b- = 30 mm. Transfer -dimension b- from the end point of dimension a- to the corner of the emblem.

Dimension -c- = 86 mm. Use -dimension c- to check the distance from the upper edge of the emblem to the edge of the wing.

Dimension -d- = 92 mm. Use -dimension d- to check the distance from the lower edge of the emblem to the edge of the wing.