Workshop Manual
Phaeton 2003 ➤
General body repairs, exterior
Edition 07.2010
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Fitting locations of adaptive cruise control senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Assembly overview - lock carrier, service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Assembly overview - lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Removing and installing lock carrier with add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Assembly overview - lock carrier attaching parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 Installation instructions for longitudinal members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Installation instructions for vehicles with adaptive cruise control . . . . . . . . . . . . . . . . . . . . 10
1.10 Removing and installing ACC senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Removing and installing front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Front wing - bolting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Assembly overview - noise insulation in vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . 18
3.3 Assembly overview - noise insulation in vehicles up to 06.2010 . . . . . . . . . . . . . . . . . . . . 19
Contents i
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
5.1 Assembly overview - lock parts with servo rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Removing and installing lock cylinder carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Lock parts with basic rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Assembly overview - lock parts with basic rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Removing and installing lock cylinder carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ii Contents
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1 Sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.4 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.5 Installing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.6 Adjusting height of sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.7 Checking parallel running of glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Adjusting parallel running of glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.9 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.10 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.11 Adjusting wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.12 Removing and installing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.13 Adjusting parallel running of sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.14 Removing and installing sliding/tilting sunroof drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.15 Adjusting drive for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.16 Removing and installing drive for sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.17 Removing and installing wind deflector drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.18 Removing and installing sliding/tilting sunroof automatic preselector . . . . . . . . . . . . . . . . 114
1.19 Removing switches for sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.20 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.21 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.22 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.23 Adapting components of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.24 Coding sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Remove sliding/tilting sunroof with solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.4 Removing sliding/tilting sunroof solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.5 Installing sliding/tilting sunroof solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.6 Adjusting sliding/tilting sunroof solar panel height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.7 Checking parallel running of solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.8 Adjusting parallel running of solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.9 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.10 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.11 Adjusting wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.12 Removing and installing solar panel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.13 Removing and installing sliding/tilting sunroof drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.14 Adjusting drive for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.15 Removing and installing wind deflector drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.16 Removing and installing sliding/tilting sunroof automatic preselector . . . . . . . . . . . . . . . . 134
2.17 Removing and installing DC-DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.18 Removing solar contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.19 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.20 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.21 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.22 Adapting components of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.23 Coding sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Contents iii
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1 Flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.3 Repairing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.4 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.5 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.6 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.7 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.8 Preparing windscreen with viewing window for chassis number for vehicles without chassis
number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.9 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.10 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.11 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.12 Preparing a removed windscreen for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.13 Preparing new window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.14 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.15 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.16 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.17 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.18 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2 Front door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.2 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.3 Removing and installing electric window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.4 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.5 Removing and installing window slot seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.6 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
iv Contents
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Contents v
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
vi Contents
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
50 – Body - front
1 Lock carrier
1.1 Tools
Note
1. Lock carrier 1
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Bolt
❑ Qty. 4
❑ 50 Nm
❑ Installation instructions
⇒ page 10 .
2 - Bolt
❑ Qty. 4
❑ 20 Nm
❑ Installation instructions
⇒ page 10 .
3 - Bolt
❑ Qty. 4
❑ 20 Nm
4 - Bolt
❑ For air ducts of air filter.
❑ Qty. 4
5 - Lock carrier with add-on
parts
6 - Guide
7 - Bolt
❑ Qty. 5
❑ 8 Nm
8 - Sender for right ACC -
G259-
❑ Removing and installing
ACC sender on right -
G259- ⇒ page 11
❑ Installation instructions
⇒ page 10 .
1. Lock carrier 3
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1. Lock carrier 5
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1.6.1 Removing
Note
1. Lock carrier 7
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
WARNING
Do not start the engine if the air conditioning system and/or the
coolant system lines are disconnected.
Note
1.6.2 Installing
1 - Lock carrier
2 - Bolt
❑ Qty. 4
❑ 20 Nm
3 - Oil cooler
4 - Hexagon nut
❑ Qty. 4
❑ 8 Nm
5 - Bolt
❑ Qty. 6
❑ 8 Nm
6 - Retaining bracket
❑ Qty. 2
7 - Expanding nut
❑ Qty. 2
8 - Air guide
9 - Bolt
❑ Qty. 2
❑ 2 Nm
10 - Bolt
❑ Qty. 4
❑ 50 Nm
11 - Hexagon nut
❑ Qty. 2
❑ 8 Nm
12 - Bolt
❑ Qty. 4
❑ 20 Nm
13 - Bolt
❑ Qty. 2
❑ 1 Nm
1. Lock carrier 9
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Note
Note
In order to remove the ACC sender on the right -G259- , the front
bumper cover must first be removed - vehicles up to 05.2010
⇒ page 143 , vehicles from 06.2010 ⇒ page 153 .
1. Lock carrier 11
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
The ACC sender on the right -G259- -3- is located behind the front
bumper carrier -1-.
– Remove the 4 bolts -4- and detach connector -2-.
– Always observe installation instructions ⇒ page 10 .
2 Wing
2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm -V.A.G 1783-
Note
2. Wing 13
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Wing
❑ Material: PUR RIM
2 - Bolt
❑ Observe tightening se‐
quence ⇒ page 17 .
❑ Qty. 15
❑ 6 Nm
3 - Foam underlay
❑ Self-adhesive.
4 - Anti-friction foil
❑ On web plate.
5 - Anti-friction foil
❑ On A-pillar.
6 - Anti-friction foil
❑ On sill.
7 - Spacer plate
❑ If necessary, use multi‐
ple spacer plates.
8 - Hexagon nut
❑ Observe tightening se‐
quence ⇒ page 17 .
❑ Qty. 7
❑ 6 Nm
2.3.1 Removing
2. Wing 15
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General body repairs, exterior - Edition 07.2010
2.3.2 Installing
Note
2. Wing 17
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
3 Noise insulation
3.1 Tools
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1783-
3. Noise insulation 19
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
WARNING
2 Bonnet
2.1 Tools
Special tools and workshop equipment required
♦ Removal lever -80 - 200-
2. Bonnet 21
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Bonnet
❑ Move bonnet to service
position ⇒ page 24
❑ Removing:
– Remove pollen filter and
retaining frame.
– Remove cables/hoses
for windscreen washer
system and washer jets.
1 - Bonnet
❑ Move bonnet to service
position ⇒ page 24
❑ Removing:
– Remove pollen filter and
retaining frame.
– Remove cables/hoses
for windscreen washer
system and washer jets.
2. Bonnet 23
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
WARNING
Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.
2.6.1 Removing
– Lever out clips -1- (Qty. 18) using removal lever -80 - 200- .
– Remove insulation -2-.
2.6.2 Installing
• The clips -1-must be fitted with the short side outwards in the
insulation -2-.
2.7.1 Removing
2. Bonnet 25
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.7.2 Installing
– Slide insulation -2- with fitting lugs into oblong holes of bonnet
-1-.
– Insert all retaining clips -3- into bonnet until they engage.
2. Bonnet 27
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Safety catch
❑ The safety catch is bol‐
ted onto the bonnet with
3 bolts
2 - Bowden cable
❑ Is divided into two by
Bowden cable coupling
-9-.
❑ The Bowden cable can
be disconnected at its
coupling in order to re‐
move the lock carrier.
❑ Disconnecting
⇒ page 35 .
3 - Release lever
❑ Removing and installing
⇒ page 35
4 - Lower A-pillar trim
5 - Bolt
❑ 6 Nm
6 - Mounting bracket
❑ Bowden cable attached.
7 - Securing clip
8 - Sealing grommet
9 - Bowden cable coupling
❑ Separating Bowden ca‐
ble ⇒ page 35
10 - Bonnet lock
❑ Removing and installing
⇒ page 29
❑ Adjusting ⇒ page 33
1 - Safety catch
❑ The safety catch is bol‐
ted onto the bonnet with
4 bolts
2 - Bowden cable
❑ It is divided in two by the
Bowden cable coupling
-9-.
❑ The Bowden cable can
be disconnected at its
coupling in order to re‐
move the lock carrier.
❑ Disconnecting
⇒ page 35 .
3 - Release lever
❑ Removing and installing
⇒ page 35
4 - Lower A-pillar trim
5 - Bolt
❑ 6 Nm
6 - Mounting bracket
❑ Bowden cable attached.
7 - Securing clip
8 - Sealing grommet
9 - Bowden cable coupling
❑ Separating Bowden ca‐
ble ⇒ page 35
10 - Bonnet lock
❑ Removing and installing
⇒ page 29
❑ Adjusting ⇒ page 33
3.3.1 Removing
Vehicles from 06.2010
– Remove radiator grille ⇒ page 217 .
– Pull Bowden cable coupling -1- from lock carrier and separate
Bowden cable ⇒ page 35 .
– Now detach the connector -1- for the contact switch for bonnet
-F266- .
Connector is located on right (in direction of travel) of lock carrier.
– Remove the 3 bolts -1- from lock carrier and remove bonnet
lock -2- upwards to left.
– Unclip contact switch 1 -F266- -1- for bonnet from bonnet lock.
When doing this, note lug -arrow A-.
– To unclip Bowden cable -3-, press tab -2- and Bowden cable
together.
– The fastening is released and you can remove the Bowden
cable from the bonnet lock.
3.3.2 Installing
Installation is carried out in reverse order.
In order to show this area of the bonnet more clearly, the bonnet
is shown in the released position.
– Now loosen 3 securing bolts -1- to correct or adjust bonnet
gaps.
Note
3.6.1 Removing
3.6.2 Installing
– First clip trim -3- at bottom into sill. Then press in upper clip.
– Secure trim with bolt -4-.
– Now the clip -6- is engaged completely in the release lever.
– Then press release lever onto mounting in bearing bracket.
4 Rear lid
4.1 Tools
Note
The hydraulic unit consists of the hydraulic pump, the lines and the hydraulic cylinders. In the event of a mal‐
function, the complete hydraulic unit must be renewed.
1 - Lid
❑ Adjusting ⇒ page 42
❑ Gap dimensions ⇒ Body
Repairs; Rep. gr. 00 ;
Technical data; Body
gap dimensions .
2 - Noise insulation
❑ Halves are bonded to‐
gether.
3 - Hydraulic pump
❑ Installed in side panel.
❑ Part of hydraulic unit.
4 - Bolt
❑ 22 Nm
5 - Retaining bracket
❑ Removing and installing
⇒ page 42
6 - Hydraulic cylinder
❑ Part of hydraulic unit.
7 - Hexagon nut
❑ 12 Nm
8 - Threaded plate
9 - Side panel
10 - Hinge
❑ Adjusting ⇒ page 42
11 - Gas strut
12 - Bolt
❑ 22 Nm
13 - Cover
14 - Bolt
❑ 22 Nm
15 - Bolt
❑ 22 Nm
16 - Cover
17 - Bolt
❑ 22 Nm
4. Rear lid 39
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
4.3.1 Removing
Note
The hydraulic unit consists of the hydraulic pump, the lines and the hydraulic cylinders. In the event of a mal‐
function, the complete hydraulic unit must be renewed.
4.3.2 Installing
Installation is carried out in reverse order.
1 - Lid
❑ Adjusting ⇒ page 42
❑ Gap dimensions ⇒ Body
Repairs; Rep. gr. 00 ;
Technical data; Body
gap dimensions .
2 - Handle trim
3 - Trim
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Removing and installing
rear lid trim
4 - Hinge
❑ Adjusting ⇒ page 42
5 - Bolt
❑ 22 Nm
6 - Hexagon nut
❑ 12 Nm
7 - Threaded plate
8 - Gas strut
❑ Removing and installing
⇒ page 42
9 - Bolt
❑ 22 Nm
❑ Releasing gas
⇒ page 42
10 - Cable duct
❑ Unbolt from rear lid and
separate connectors.
11 - Adjustment buffer
❑ The part called "adjustment buffer" in other vehicles is not for adjusting the rear lid. They have the function
of stabilising and damping the rear lid. The adjusting buffer is referred to as damper below.
❑ Before removing, remove trim.
❑ Removing
❑ Turn adjustment buffer by 90 degrees using a ring spanner (24 mm) and take out of shaped hole.
❑ Adjusting ⇒ page 42
4. Rear lid 41
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
WARNING
Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
Note
– Lift up locking clip -1- using screwdriver and pull gas strut off
ball-head pins -3-.
Note
4. Rear lid 43
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Note
♦ The rear lid is adjusted correctly if the gaps/shut lines are even
all around, the lid is not too deep or too high and all contours
align when the lid is closed.
♦ Vehicle must be standing on its wheels when adjustments are
performed.
Note
♦ The rear lid is adjusted correctly if the gaps/shut lines are even
all around, the lid is not too deep or too high and all contours
align when the lid is closed.
♦ Vehicle must be standing on its wheels when adjustments are
performed.
Note
♦ The rear lid is adjusted correctly if the gaps/shut lines are even
all around, the lid is not too deep or too high and all contours
align when the lid is closed.
♦ Vehicle must be standing on its wheels when adjustments are
performed.
– Press covers -2- down. Using special tool 3320/3, you can
loosen striker plate bolts -1- and move it in oversized holes.
– Close rear lid and check the adjustment.
For vehicles with servo opener, you can close or open rear lid
either via contact switch in rear lid or remote control key.
– Following adjustment, retighten bolts -1- to specified torque
setting.
Bolt -1- 20 Nm
4. Rear lid 45
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
5.1 Assembly overview - lock parts with servo rear lid opener
Note
5.2.1 Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing rear lid trim .
– Separate connectors -3-.
– Remove securing bolts -2- for retaining clip.
– Now loosen bolts -1- until retaining clip can be removed from
lock cylinder carrier over key holes in direction of arrow.
– Now lock cylinder carrier can be removed from outside.
5.2.2 Installing
– Insert lock cylinder carrier into lid.
– Now join retaining clip to carrier and lightly tighten bolts -1-
against retaining clip.
– After starting bolts -2- and lightly tightening them against lid,
lock cylinder carrier can be centred from outside by pushing it
within aperture in lid.
Note
5.3.1 Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing rear lid trim .
– Disconnect connection -1- and remove bolts 2 and -3-.
– Remove rear lid lock.
5.3.2 Installing
Note
6.1 Assembly overview - lock parts with basic rear lid opener
Note
6.2.1 Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing rear lid trim .
– Detach connectors -4- and-5-.
– Remove securing bolts -3- for retaining clip.
– Now loosen bolts -2- until retaining clip can be removed from
lock cylinder carrier over key holes in direction of arrow.
– Release securing element -1- and separate coupling rod.
– Now lock cylinder carrier can be removed from outside.
6.2.2 Installing
– Insert lock cylinder carrier into lid.
– Now join retaining clip to carrier and lightly tighten bolts -2-
against retaining clip.
– After starting bolts -3- and lightly tightening them against lid,
lock cylinder carrier can be centred from outside by pushing it
within aperture in lid.
Note
6.3.1 Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing rear lid trim .
– Disconnect connections -1- and unbolt bolts 2 and -3-.
– Release securing element and separate coupling rod.
– Remove rear lid lock.
6.3.2 Installing
– Insert lid lock.
Note
7.1 Tools
Special tools and workshop equipment required
♦ Socket -T 10010-
6 - Seal
7 - Tank flap cup
❑ Removing and installing (can only be removed as part of tank flap unit)
❑ Press out securing pin in tank flap unit to remove the tank flap
8 - Positioning element bracket
9 - Fuel filler flap positioner
❑ Loosen with special tool hexagon socket screwdriver -T 10010- .
WARNING
2 Front door
2.1 Tools
2. Front door 55
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Note
♦ Spacer plates are located behind the upper door hinge and the door. The spacer plates have varying thick‐
nesses. Consequently, the door hinge must be loosened only on rare occasions.
♦ The hinge bolts must always be renewed if loosened.
1 - Door
❑ Removing and installing
⇒ page 58
2 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
3 - Multi-point socket head bolt
❑ Remove only this bolt
from hinge to remove
door.
❑ M8×28
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
4 - Door hinge with arrester
❑ Hinge is split.
5 - Multi-point socket head bolt
❑ M8×28
❑ Installed from inside ve‐
hicle.
❑ Removing A-pillar lower
trim ⇒ General body re‐
pairs, interior; Rep. gr.
70 ; Pillar and side panel
trim
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
6 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
❑ Always renew bolts after loosening.
7 - Hexagon nut
❑ 23 Nm
8 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
2. Front door 57
Phaeton 2003 ➤
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2.3.1 Removing
Note
2.3.2 Installing
Installation is carried out in reverse order.
Note
Note
2. Front door 59
Phaeton 2003 ➤
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1 - Door lock
❑ The door lock can be re‐
moved only together
with the assembly carri‐
er.
❑ Removing and installing
⇒ page 65
2 - Bolt
❑ 20 Nm
3 - Retaining screw
❑ This bolt provides addi‐
tional security for the
lock cylinder housing.
❑ Only on vehicles with
lock cylinder.
4 - Multi-point socket head bolt
❑ Socket -T 10072-
❑ Undoing this screw re‐
lease the catch for lock
cylinder housing -6-,
which can then be with‐
drawn from the bearing
bracket -12-.
❑ Screw -4- must not be
screwed in without the
lock cylinder housing
being inserted.
5 - Base
6 - Lock cylinder housing
❑ Removing ⇒ page 61
❑ Lock cylinder is not sup‐
plied as individual parts.
❑ Lock cylinder only on
driver side.
7 - Key
❑ Changing battery ⇒ page 75 .
❑ Adapting new or additional key to remote control ⇒ page 75 .
8 - Door handle
❑ Removing and installing ⇒ page 63
❑ Door handle with (Keyless Entry) cable routing ⇒ page 65 .
9 - Base
10 - Cable (Keyless Entry)
❑ Exterior door handle with driver side cable routing ⇒ page 65 .
❑ Exterior door handle with front passenger side cable routing ⇒ page 65 .
11 - Bolt
❑ 6 Nm
12 - Bearing bracket
❑ Removing:
Door handle, lock cylinder housing and door assembly carrier have been removed.
❑ Remove bolt -11-, push back bearing bracket slightly and take it out of door.
13 - Cover
❑ Not supplied with door lock.
14 - Bowden cable
❑ Lock release
15 - Retaining bracket
❑ Bolted and riveted to door lock.
❑ Not supplied with door lock.
2.7.1 Removing
– Lever off cap -1-.
2. Front door 61
Phaeton 2003 ➤
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– Pull door handle -1- and hold it. Unscrew bolt -3- onto stop
using socket insert -T 10072- . Lock cylinder housing -2- is now
released.
– Now loosen bolt -1- until lock cylinder housing -2- can be pulled
out of door handle bearing bracket at right angles.
2.7.2 Installing
– Insert lock cylinder housing at right angle into door handle
bearing bracket.
– Turn screw into bearing bracket with socket wrench.
The door handle engages in the lock cylinder housing with an
audible click.
– The lock cylinder housing must then be secured with bolt -1-;
see top part of illustration.
Note
2.8.1 Removing
Removing and installing lock cylinder housing ⇒ page 61 .
– Door handle with (Keyless Entry) cable routing ⇒ page 65 .
– Unclip clip -1- from door handle -2-.
– Swing door handle out of door.
2.8.2 Installing
2. Front door 63
Phaeton 2003 ➤
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Note
1 - Window frame
❑ Remove window frame
⇒ General body repairs,
interior; Rep. gr. 70 ;
Trims, insulation; Re‐
moving and installing
door linings .
2 - Wiring harness
❑ Secured in upper door
area with cable tie.
❑ Removing assembly
carrier -4- ⇒ page 65 .
3 - Connector (Keyless Entry)
4 - Assembly carrier
2. Front door 65
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
The door lock can be removed only together with the assembly
carrier.
Assembly carrier can only be removed when door window is un‐
bolted at window regulator clamping bolts. To do this, lower door
window to the height of the assembly holes in assembly carrier
and loosen clamping bolts.
2.10.1 Removing
– Remove front door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Trims, insulation; Removing and
installing door trim .
– Removing lock cylinder housing ⇒ page 61
– Unclip clip -1- from door handle.
Note
If the work step cannot be carried out because there is a fault with
the electric window motor, remove motor to slide window down.
Note
The retaining bracket is not part of the items supplied with the
door lock. Secured to door lock with a bolt and a pop rivet.
2.10.2 Installing
2. Front door 67
Phaeton 2003 ➤
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Note
Hooking the operating lever in locks the lock. This prevents „incorrect“ attachment of the Bowden cable later.
Note
– Insert all bolts. Tighten bolts -1- and -2- in the order specified
to specified torque 8 Nm.
– The remaining bolts can be tightened in any sequence.
– Press door window -3- into window channel -arrow- and tight‐
en clamping bolts -4- (Qty. 2) (10 Nm).
– Then perform remaining installation in reverse order of remov‐
al.
• Test function before installing door trim.
2. Front door 69
Phaeton 2003 ➤
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1 - Door
2 - Assembly carrier
3 - Door power latching motor
(V 278)
4 - Bolt
❑ Qty. 4
❑ 3.5 Nm
5 - Connector
6 - Bowden cable
Note
♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, a tight seal is not guaranteed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called „tap-on“ seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.
2.13.1 Removing
– Remove the pillar trims as required ⇒ General body repairs,
interior; Rep. gr. 70 ; Pillar trim
– Remove sill panel mouldings ⇒ General body repairs, interior;
Rep. gr. 68 ; Interior equipment; Sill panel mouldings .
– Remove interior door seal from body flange.
2.13.2 Installing
– When installing door inner seal, start at upper radius of the
door aperture.
Note
2.14.1 Removing
– To remove door outer seal, door trim, both carrier frames and
window frame trim must be removed ⇒ General body repairs,
interior; Rep. gr. 70 ; Trims, insulation; Removing and instal‐
ling door trim .
– Pull door outer seal off door flange.
2. Front door 71
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.14.2 Installing
– Remove existing adhesive residues with erasure disc of ad‐
hesive strip remover -VAS 6349- .
– Immediately before bonding door outer seal, clean 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.
– To apply door outer seal, align coloured mark of seal with se‐
curing bolt -1- of window slot seal.
– Pull protective sheeting off in stages, then apply seal to door
flange and bond. Do not pull door outer seal to avoid stretching
seal.
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
♦ The insulation elements have the task of minimising noise and ensuring good sealing qualities. For this
reason, it is important to ensure that only serviceable insulation elements are installed and in the correct
position.
♦ The bonded insulation elements should always be renewed.
♦ Inserted damping parts are to be checked for damage, e.g. cracks, and renewed if necessary.
2. Front door 73
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Door
2 - Sealing strip
❑ Bonded to A-pillar.
❑ Self-adhesive.
3 - Insulation
❑ Removing and installing
⇒ page 74
4 - Sound suppression
❑ Self-adhesive.
5 - Insulation
❑ Inserted in upper area of
B-pillar.
Note
2.18.1 Removing
– Insert a screwdriver in the slot between the transmitter unit
-1- and the main key -2-.
– Move the screwdriver in direction of arrow and unclip the
transmitter unit from the main key.
2. Front door 75
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.18.2 Installing
Observe polarity and correct position when installing the batter‐
ies.
– Place the battery with the positive terminal downwards in the
transmitter unit (positive terminal is marked on housing).
– Engage battery in transmitter unit by pressing down lightly.
– Fit cover to transmitter unit (do not damage seal).
– Then engage the transmitter unit with the main key.
2.19 Assembly overview - batteries for main key (foldable) with remote control,
vehicles from 01.2004
2.20.1 Removing
– Insert a small screwdriver in the gap between cap -1- and key
-2-.
– Push the screwdriver in -direction of arrow- and prise cap off
key.
2. Front door 77
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.20.2 Installing
Note polarity and correct position when installing battery.
– Insert battery -1- in key -2- in -direction of arrow- with the pos‐
itive pole underneath.
– Press lightly on the battery to engage it in the key.
– Now fit the cover to the key.
2.21 Assembly overview - batteries for main key (foldable) with remote control,
vehicles from 06.2010
2.22.1 Removing
– Insert a small screwdriver in the gap between cap -1- and key
-2-.
– Turn the screwdriver in -direction of arrow- and prise cap -1-
off key -2-.
2. Front door 79
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.22.2 Installing
Note
WARNING
1. Contact corrosion! 81
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2 Rear door
2.1 Tools
Note
♦ Spacer plates are located behind the upper door hinge and the door. The spacer plates have varying thick‐
nesses. Consequently, the door hinge must be loosened only on rare occasions.
♦ The hinge bolts must always be renewed if loosened.
1 - Door
❑ Removing and installing
⇒ page 84
2 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
3 - Multi-point socket head bolt
❑ Remove only this bolt
from hinge to remove
door.
❑ M8×28
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
4 - Door hinge with arrester
❑ Hinge is split.
5 - Multi-point socket head bolt
❑ M8×28
❑ Installed from inside ve‐
hicle.
❑ Removing A-pillar lower
trim ⇒ General body re‐
pairs, interior; Rep. gr.
70 ; Pillar and side panel
trim
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
6 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
❑ Always renew bolts after loosening.
7 - Hexagon nut
❑ 23 Nm
8 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
2. Rear door 83
Phaeton 2003 ➤
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❑ Always renew bolts after loosening.
9 - Door hinge
❑ Hinge is split.
10 - Multi-point socket head bolt
❑ M8×22
❑ Installed from inside vehicle.
❑ To loosen or tighten bolt, remove and install dash panel ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel; Removing and installing dash panel .
❑ 20 Nm + 1/4 turn further (90°).
❑ Always renew bolts after loosening.
11 - Hexagon nut
❑ 23 Nm
12 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
❑ Always renew bolts after loosening.
13 - Door hinge
❑ Hinge is split.
14 - Spacer plate
❑ With material thicknesses of 0.5 mm, 1.0 mm and 1.5 mm.
2.3.1 Removing
– Remove B-pillar lower trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Pillar and side panel trim
– Unbolt seat belt height adjustment motor V233 -1-.
– Separate connectors -2- and unclip wiring harness.
– Pull boot -3- off B-pillar. Now electrical wiring can be guided
out of B-pillar.
– Remove nuts -1- from door hinges and remove bolt -2- from
hinge.
Specified torque = 20 Nm + 1/4 turn (90°) further
Note
2.3.2 Installing
Installation is carried out in reverse order.
Note
2. Rear door 85
Phaeton 2003 ➤
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Note
1 - Door lock
❑ The door lock can be re‐
moved only together
with the assembly carri‐
er.
❑ Removing and installing
⇒ page 91
❑
2 - Cable
❑ Lock release
3 - Bowden cable
4 - Retaining bracket
❑ Bolted and riveted to
door lock.
❑ Not supplied with door
lock.
5 - Bearing bracket
❑ Removing:
Door handle, lock cylinder
housing and door assembly
carrier have been removed.
❑ Remove bolt -6-, slide
bearing plate -5- slightly
to rear and remove from
door.
6 - Bolt
7 - Base
8 - Door handle
❑ Removing and installing
⇒ page 88
❑ Door handle with (Key‐
less Entry) cable routing ⇒ page 90 .
9 - Housing
❑ Removing ⇒ Removing lock cylinder housing on page ⇒ page 61
10 - Base
11 - Multi-point socket head bolt
❑ This screw has been replaced by a Torx screw. The new tool was introduced as a result.
❑ Socket wrench -T 10072- .
❑ Loosening this bolt releases the catch for housing -9-, which can then be withdrawn from the bearing
bracket -5-.
❑ Screw -11- must not be screwed in without the lock cylinder housing being inserted. Otherwise the locking
ring may fall into the door.
2. Rear door 87
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.7.1 Removing
– Pull off door seal -1- in area of door handle.
– Pull door handle -2- in -direction of arrow- and hold.
– Unscrew bolt -4- onto stop using socket insert -T 10072- . This
releases the lock cylinder housing.
– Door handle with (Keyless Entry) cable routing ⇒ page 90 .
Note
Unscrewing the bolt too far may cause the locking ring to release
from the bearing bracket and fall into the door.
– Pull housing -3- at right angle to door out of door handle bear‐
ing plate.
2.7.2 Installing
2. Rear door 89
Phaeton 2003 ➤
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Note
Note
1 - Door
2 - Assembly carrier
3 - Connector (Keyless Entry)
4 - Wiring harness
❑ Secured in upper door
area with cable tie.
❑ Removing assembly
carrier -2- ⇒ page 91 .
2.9.1 Removing
– Remove rear door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Removing and installing door trim .
2. Rear door 91
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Note
Unscrewing the bolt too far may cause the locking ring to release
from the bearing bracket and fall into the door.
– Pull housing -3- at right angle to door out of door handle bear‐
ing plate.
Note
If the work step cannot be carried out because there is a fault with
the electric window motor, remove motor to slide window down.
Note
The retaining bracket is not part of the items supplied with the
door lock. Secured to door lock with a bolt and a pop rivet.
2. Rear door 93
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.9.2 Installing
Note
Hooking the operating lever in locks the lock. This prevents „incorrect“ attachment of the Bowden cable later.
2. Rear door 95
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Door
2 - Assembly carrier
3 - Bolt
❑ Qty. 4
❑ 3.5 Nm
4 - Door power latching motor
(V 278)
5 - Connector
6 - Bowden cable
Note
♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, a tight seal is not guaranteed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called „tap-on“ seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.
2.12.1 Removing
– Remove the pillar trims as required ⇒ General body repairs,
interior; Rep. gr. 70 ; Pillar trim
– Remove sill panel mouldings ⇒ General body repairs, interior;
Rep. gr. 68 ; Interior equipment; Sill panel mouldings .
– Remove interior door seal from body flange.
2.12.2 Installing
– When installing door inner seal, start at upper radius of the
door aperture.
Note
2.13.1 Removing
– To remove door outer seal, door trim, both carrier frames and
window frame trim must be removed ⇒ General body repairs,
interior; Rep. gr. 70 ; Removing and installing door trim .
– Pull door outer seal off door flange.
2. Rear door 97
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
2.13.2 Installing
– Remove existing adhesive residues with erasure disc of ad‐
hesive strip remover -VAS 6349- .
– Immediately before bonding door outer seal, clean 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.
– To apply door outer seal, align coloured mark of seal with se‐
curing bolt -1- of window slot seal.
– Pull protective sheeting off in stages, then apply seal to door
flange and press. Do not pull door outer seal to avoid stretch‐
ing seal.
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
♦ The insulation elements have the task of minimising noise and ensuring good sealing qualities. For this
reason, it is important to ensure that only serviceable insulation elements are installed and in the correct
position.
♦ The bonded insulation elements should always be renewed.
♦ Inserted damping parts are to be checked for damage, e.g. cracks, and renewed if necessary.
2. Rear door 99
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Door
2 - Insulation
❑ Inserted in upper area of
B-pillar.
3 - Sealing strip
❑ Bonded to B-pillar.
❑ Self-adhesive.
4 - Insulation
❑ Removing and installing
⇒ page 100
5 - Sound suppression
❑ Self-adhesive.
6 - Insulation
❑ Mounted on centre
cross member.
7 - Insulation
❑ Inserted in C-pillar.
8 - Decorative film
❑ For bottom area.
9 - Decorative film
❑ For upper area.
10 - Insulation
❑ Inserted in bottom area
of C-pillar.
60 – Sunroof
1 Sunroof with glass panel
1.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm -V.A.G 1783-
1.2 Function
All functions of the sliding/tilting sunroof with glass panel can be
performed with ignition switched on.
After ignition is switched off, the functions can be performed until
either the driver or front passenger door is opened.
1 - Carrier unit
❑ Removing carrier unit
⇒ page 117 .
❑ U-frame with guide
channels: grease guide
channels as required
with special grease G
000 450 02 only. Other‐
wise correct operation
cannot be guaranteed.
2 - Slide with cable
❑ For guide plate.
❑ Cables cannot be re‐
newed separately, but
only together with the
assembly unit.
3 - Slide with cable
❑ For sun visor.
❑ Cables cannot be re‐
newed separately, but
only together with the
assembly unit.
4 - Wind deflector mounting
❑ Adjusting ⇒ page 108
5 - Wind deflector
❑ Removing ⇒ page 107
6 - Bolt
7 - Cover
8 - Sliding headliner
❑ Removing and installing
sliding headliner
⇒ page 108
9 - Cover
❑ For guide plate.
10 - Guide plate
❑ Part of assembly unit. Cannot be renewed separately.
11 - Glass panel for sliding/tilting sunroof (single pane safety glass)
❑ Removing sliding/tilting sunroof glass panel ⇒ page 104 .
❑ Installing sliding/tilting sunroof glass panel ⇒ page 104 .
❑ Adjusting sliding/tilting sunroof glass panel ⇒ page 105
❑ Renewing panel seal ⇒ page 107 .
12 - Retaining bracket
13 - Drive for sliding/tilting sunroof
❑ Removing ⇒ page 110
❑ Check drive (0 position) ⇒ page 111 .
14 - Water channel
❑ Part of assembly unit. Cannot be renewed separately.
15 - Crank for emergency operation
❑ Clipped into cover for electric drive.
16 - Drive for sunroof roller blind
❑ Removing ⇒ page 112
17 - Electrical wiring
18 - End piece
19 - Bolt
20 - Electrical wiring
21 - Wind deflector drive
❑ Removing ⇒ page 110
22 - Bolt
23 - Extender mechanism
❑ For wind deflector.
24 - Seal
❑ For assembly unit.
Zero position:
The guide pins -1- must lie between the markings on the guide
plate -arrow-.
If this is not the case, adjust parallel running ⇒ page 106 .
Note
Note
Note
1.10.1 Removing
– Open sunroof completely.
– Applying force on left and right about 20 cm inwards measured
from roof cut-out -arrows-, push wind deflector backwards.
Lever out both retaining brackets below positioning mecha‐
nism -1- for wind deflector and lift out of roof edge.
1.10.2 Installing
– Adapt components ⇒ page 121
1.12.1 Removing
– Removing glass panel for sunroof ⇒ page 104 .
– Move sliding headliner forwards as far as possible.
1.12.2 Installing
– Adapt components ⇒ page 121
1.14.1 Removing
– Switch off ignition.
Note
Remove and install drive for sliding/tilting sunroof only when roof
is closed ("0" position).
– Remove bolts -2- and pull off drive -1- for sliding/tilting sunroof.
– Unclip and separate connector -3-.
The screws for the drive are microencapsulated and must always
be renewed 3.5 Nm.
1.14.2 Installing
– Adapt components ⇒ page 121
1.16.1 Removing
– Switch off ignition.
– Using a small screwdriver, release the locking mechanism at
the front -arrows- of the cover of the rear light and control unit.
– Remove bolts -2- and pull off drive for sliding headliner -1-.
– Unclip and separate connector.
The screws for the drive are microencapsulated and must always
be renewed 3.5 Nm.
1.16.2 Installing
– Adapt components ⇒ page 121
1.17.1 Removing
– Open sunroof completely.
– Switch off ignition.
– Using a small screwdriver, release interior light glass locking
mechanism in front -arrow- of front lights and operating unit.
1.17.2 Installing
– Adapt components ⇒ page 121
1.18.1 Removing
– Switch off ignition.
– On the back of the light and control unit, the rectangular com‐
ponent is first unclipped and swung to side.
1.18.2 Installing
– Adapt components ⇒ page 121
1.19.1 Removing
– Switch off ignition.
– Using a small screwdriver, release interior light glass locking
mechanism in front -arrow- of front lights and operating unit.
– On the back of the light and control unit, the rectangular com‐
ponent is first unclipped -arrows- and swung to side.
– Remove four bolts -arrows- for one of the two reading lights
and remove reading light.
1.19.2 Installing
– Adapt components ⇒ page 121
1.20.1 Removing
1.20.2 Installing
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– Using cylindrical dowel pins (inverted drill bits) align the carrier
unit 10 mm from the roof frame at the front right -5- and 12 mm
at the front left -2-. Carrier unit must not contact roof frame.
– Check routing of wiring and connections of electrical consum‐
ers in roof and restore if necessary.
– Tighten bolts to 8 Nm for carrier unit -1-, starting at tilting/slid‐
ing sunroof drive -4- and moving towards the rear, alternating
between the left and right-hand side.
– Remove cylindrical pins -2- and -5-.
The front water drain hoses run through the A-pillars and end at
the engine bulkhead. Cleaning is done from the sunroof panel
aperture.
Note
For cleaning, a locally manufactured tool made from a speedometer inner cable, approx. 2300 mm long is
recommended.
The rear water drain hoses run through the C-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.
Note
For cleaning, a locally manufactured tool made from a speedometer inner cable, approx. 2300 mm long is
recommended.
2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm -V.A.G 1783-
2.2 Function
All the movement functions of the sliding/tilting sunroof with solar
panel can be carried out with the ignition switched on.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.
Opening the solar panel in the sliding and tilting positions is pre‐
selected with the rotary switch. The panel covering is an integral
part of the solar panel and cannot be moved separately.
The wind deflector also has its own drive. This drive extends the
wind deflector depending on the opening position of the solar
panel as well as the vehicle speed. When the vehicle is being
driven, a gap may develop between the vehicle roof and the wind
deflector. This intentional gap reduces noise.
All electrically driven sliding/tilting sunroof components are fitted
with an anti-trap circuit. The glass panel ??? from its tilted posi‐
tion.
In addition, there is an emergency closure function. If problems
occur during closure, the sunroof can be forced to shut by press‐
ing the pre-selector switch when it is in the „close sunroof“ posi‐
tion.
The anti-trap mechanism works with raised clamping forces in the
emergency closure function.
The sunroof drive is protected against overheating by a time lim‐
itation. The protective mechanism activates when the sunroof is
operated continuously for approx. 2 minutes. It is functional again
after a cooling-off phase.
In the event of power failure, the sunroof can be moved using a
crank directly on the drive. This crank is attached to the inside of
the rear interior light trim.
The solar cells -1- integrated in the solar panel of the sliding/tilting
sunroof generate a high voltage when exposed to the sun. The
DC converter -2- incorporated in the solar panel provides a suit‐
ably modified voltage for the vehicle fan. This only works when
the ignition is switched off and the solar panel is tilted or closed.
1 - Carrier unit
❑ Removing carrier unit
⇒ page 136 .
❑ U-frame with guide
channels: grease guide
channels as required
with special grease G
000 450 02 only. Other‐
wise correct operation
cannot be guaranteed.
2 - Slide with cable
❑ For guide plate.
❑ Cables cannot be re‐
newed separately, but
only together with the
assembly unit.
3 - Slide with cable
❑ For sun visor.
❑ Not installed with solar
panel.
4 - Wind deflector mounting
❑ Adjusting ⇒ page 130
5 - Retaining bracket
❑ For panel trim.
6 - Wind deflector
❑ Removing ⇒ page 129
7 - Bolt
8 - Cover
9 - Panel covering
❑ Removing and installing
panel covering
⇒ page 130
10 - Solar contact
❑ On panel.
11 - Cover
❑ Not installed with solar panel.
12 - Guide plate
❑ Part of assembly unit. Cannot be renewed separately.
13 - Solar panel for sliding/tilting sunroof (single pane safety glass)
❑ Remove sliding/tilting sunroof solar panel ⇒ page 126 .
❑ Installing the sliding/tilting sunroof solar panel ⇒ page 126 .
❑ Adjusting the sliding/tilting sunroof solar panel ⇒ page 127 .
❑ Renewing panel seal ⇒ page 129 .
14 - DC-DC converter
15 - Retaining bracket
16 - Drive for solar panel
❑ Removing ⇒ page 131
❑ Adjusting drive ("0" position) ⇒ page 132 .
17 - Water channel
❑ Part of assembly unit. Cannot be renewed separately.
Zero position:
The guide pins -1- must lie between the markings on the guide
plate -arrow-.
If this is not the case, adjust parallel running ⇒ page 128 .
Note
Note
Note
2.10.1 Removing
– Open sunroof completely.
– Applying force on left and right about 20 cm inwards measured
from roof cut-out in -direction of arrows-, push wind deflector
backwards. Lever out both retaining brackets below position‐
ing mechanism -1- for wind deflector and lift out of roof edge.
2.10.2 Installing
– Adapt components ⇒ page 140
2.12.1 Removing
– Open sliding/tilting sunroof about 10 cm rearwards.
– Pull trim -1- downwards in the middle -arrow- out of mounting
-2-.
– Push trim forwards.
– Move sliding/tilting sunroof back.
2.12.2 Installing
– Adapt components ⇒ page 140
2.13.1 Removing
– Switch off ignition.
– Using a small screwdriver, release the locking mechanism at
the front -arrows- of the cover of the rear light and control unit.
Note
Remove and install drive for sliding/tilting sunroof only when roof
is closed ("0" position).
– Remove bolts -2- and pull off drive -1- for sliding/tilting sunroof.
– Unclip and separate connector -3-.
The screws for the drive are microencapsulated and must always
be renewed 3.5 Nm.
2.13.2 Installing
– Adapt components ⇒ page 140
2.15.1 Removing
– Open sunroof completely.
– Switch off ignition.
2.15.2 Installing
– Adapt components ⇒ page 140
2.16.1 Removing
– Switch off ignition.
– Using a small screwdriver, release interior light glass locking
mechanism in front -arrow- of front lights and operating unit.
– On the back of the light and control unit, the rectangular com‐
ponent is first unclipped -arrows- and swung to side.
2.16.2 Installing
– Adapt components ⇒ page 140
2.17.1 Removing
– Removing the sliding/tilting sunroof solar panel ⇒ page 126 .
– Remove the four bolts -4- for retaining braces -6-.
– Remove retaining braces.
– Pull connector off DC-DC converter -7-.
2.17.2 Installing
– Adapt components ⇒ page 140
– Tip solar contact -2- with bracket and remove from retainer.
– Pull connector off DC-DC converter.
2.19.1 Removing
2.19.2 Installing
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– Using cylindrical dowel pins (inverted drill bits) align the carrier
unit 10 mm from the roof frame at the front right -5- and 12 mm
at the front left -2-. Carrier unit must not contact roof frame.
– Check routing of wiring and connections of electrical consum‐
ers in roof and restore if necessary.
– Tighten bolts to 8 Nm for carrier unit -1-, starting at tilting/slid‐
ing sunroof drive -4- and moving towards the rear, alternating
between the left and right-hand side.
– Remove cylindrical pins -2- and -5-.
– Fit water drain hoses.
– Fit connector for drives -4-.
The front water drain hoses run through the A-pillars and end at
the engine bulkhead. Cleaning is done from the sunroof panel
aperture.
Note
For cleaning, a locally manufactured tool made from a speedometer inner cable, approx. 2300 mm long is
recommended.
The rear water drain hoses run through the C-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.
Note
For cleaning, a locally manufactured tool made from a speedometer inner cable, approx. 2300 mm long is
recommended.
63 – Bumpers
1 Front bumper cover of vehicles up to
05.2010
Note
1.2 Tools
Special tools and workshop equipment required
♦ Socket -T10113-
Note
There may be minor differences between bumper covers, depending on vehicle model.
Note
1.4.1 Removing
1.4.2 Installing
12 - Retaining clip
❑ For chrome strip
Note
Note
In order to remove the ACC sensor on the right -G259- , the front
bumper cover must first be removed ⇒ page 143 .
The ACC sender on the right -G259- -3- is located behind the front
bumper carrier -1-.
– Remove the 4 bolts -4- and detach connector -2-.
– Always observe installation instructions ⇒ page 148 .
Note
For vehicles with automatic adaptive cruise control, ensure that corresponding radar-compatible bumper cover
insert is used.
Note
– Engage grid -2- on bumper cover insert -1-. Ensure that all
retaining hooks engage correctly.
– Pull off protective backing from adhesive tape -3-.
– Engage chrome strip -4- on bumper cover insert -1-. Ensure
that all retaining hooks engage correctly.
– Press chrome strip -4- forcefully on bumper cover insert -1- in
area of adhesive tape -3-.
– Tighten bolts -5-. Specified torque: 2 Nm
Note
2.2 Tools
Special tools and workshop equipment required
♦ Socket -T10113-
Note
There may be minor differences between bumper covers, depending on vehicle model.
Note
2.4.1 Removing
2.4.2 Installing
Note
3.2 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm -V.A.G 1783-
Note
The removal and installation procedures may have to be modified slightly depending on variations in equipment.
3.4.1 Removing
3.4.2 Installing
1 - Bumper carrier
2 - Hexagon nut
❑ Qty. 8
❑ 20 Nm
3 - Securing strip
4 - Bolt
❑ Qty. 9
❑ 2 Nm
5 - Bolt
❑ Qty. 5
❑ 2 Nm
6 - Guide
❑ To remove and install,
pull out/push in rear
bumper cover parallel to
guide elements (left and
right)
7 - Expanding nut
❑ Qty. 5
8 - Expanding nut
❑ Qty. 9
9 - Retaining bracket
❑ Qty. 2
10 - Bolt
❑ Qty. 2
❑ 8 Nm
Note
WARNING
1 - Towing bracket
2 - Ball coupling
❑ The removable ball
head can be found in a
separate mounting box
in the left luggage com‐
partment bin.
3 - Bolt
❑ Qty. 3 per side
❑ 50 Nm + turn 90° further
64 – Glazing
1 Flush bonded windows
1.1 Tools
1.2 Materials
♦ 2K glass adhesive DA 004 600 A2 2) 1),3)
♦ 1K glass adhesive DH 009 100 034) 2),5)
♦ Activator D 181 801 A1 1)
Note
1 - Windscreen
❑ Removing windscreen
⇒ page 174
❑ Installing windscreen
⇒ page 175
2 - Dimension a = 2 mm
3 - Sealing lip
❑ If windscreen is to be re-
used, damage to seal‐
ing lip must be avoided.
4 - PUR adhesive sealant
❑ Cross section of bead:
width = 8 mm, height =
10 mm (including resid‐
ual material on window
glass and window
flange).
❑ Use new mixing nozzle
to apply sealant bead.
❑ Minimum curing period
⇒ page 182 .
5 - Windscreen adjuster
❑ 443 845 631 A
6 - Plenum chamber cover
❑ Clipped
❑ The plenum chamber
cover must be pulled off
only by hand
❑ Removing and installing
plenum chamber cover
⇒ page 169
7 - Water deflector
1.5.1 Removing
– Remove windscreen wiper arms -1- ⇒ Electrical system; Rep.
gr. 92 ; Windscreen wiper/washer system; Windscreen wiper
system; Removing windscreen washer system
– Undo the four rotary catches -arrows- of the additional cover.
– Lift additional cover and pull it upwards out of clearances to
left and right of cross member.
Note
The plenum chamber cover must not be levered off with a tool (wedge). The windscreen will be damaged and
may subsequently crack.
1.5.2 Installing
Note
Striking the plenum chamber cover can cause cracks in the wind‐
screen.
Note
♦ Make sure that no wiring is damaged when the windscreen is cut out. If wires are damaged, the windscreen
must be renewed.
♦ Ensure that the sealing lip is not damaged when the windscreen is cut out. If the sealing lip is damaged, the
windscreen must be renewed.
Note
– Secure one end of the cord to the reel device -V.A.G 1654- .
– Pull the other end of the thread through into the interior and
pull against with the handle -V.A.G 1351/1- .
– Place reel device -V.A.G 1654- in„Position I“.
– Move reel device according to position required and cut win‐
dow free.
– Press cutting cord against windscreen with a plastic wedge
while cutting.
1 - Rear window
❑ Removing rear window
⇒ page 178 .
❑ Installing rear window
⇒ page 179 .
2 - Sealing lip
❑ Due to the narrow gap to
edge of roof, damage to
the sealing lip must be
avoided.
3 - PUR adhesive sealant
❑ Cross section of bead:
width = 8 mm, height =
10 mm (including resid‐
ual material on window
glass and window
flange)
❑ Minimum curing period
⇒ page 182 .
4 - Dimension a = 2 mm
Note
– Pull the other end of the cord through into the interior and
counterhold using handle -V.A.G 1351/1- .
– Secure inner end of cord on reel device.
– Move reel device according to position required and cut win‐
dow free.
– Press cutting cord against window glass with plastic wedge
during cutting process, in order to have clearance at window
flange.
WARNING
Note
WARNING
Activator must not have contact with paint or the paintwork will
be damaged.
Note
It is possible that a laser weld seam lies outside the area of the
adhesive bead. In this case, the exposed weld seam must be
sealed with window adhesive before bonding the window.
– Apply adhesive all round on the primed area -1- and/or cut-
back adhesive at right angles to the windscreen.
WARNING
♦ With help of two suction cups -V.A.G 1344- , install glass pane
in window aperture, align to centre and press in onto the spac‐
ing lip.
♦ The gap for the windscreen at the top is 2 mm.
♦ The gap for the rear window at the top and sides is 2 mm.
♦ Secure windscreen during curing period with window adjusters
-443 845 631 A- .
♦ It is absolutely necessary to install the plenum chamber cover
as described on page ⇒ page 169 .
♦ Replace stickers (e.g. for airbag) which may be installed.
♦ Use adhesive tape to secure rear window in position while
curing.
♦ If the adhesive bead is too thick and the adhesive expands
onto the area of the window heating, excess adhesive must
be removed.
WARNING
The minimum curing period for the 2K adhesive -DA 004 600 A2-
is three hours for all windows.
Minimum curing period is the time from bonding the window until
vehicle may be used. During this time, the vehicle must stand on
a level surface at room temperature (at least 15 °C).
WARNING
WARNING
When cleaning freshly installed glass from the inside in the ve‐
hicle, do not press glass outwards.
1 - Window channel
❑ Pushed onto flange.
2 - Trim strip
❑ Clipped to window slot
seal.
3 - Cross-head screw
4 - Window slot seal
❑ Pushed onto flange.
❑ Removing ⇒ page 192
5 - Trim
❑ Removing ⇒ page 192
6 - Bolt
❑ Qty. 2.
❑ 3.5 Nm
7 - Trim
8 - Insulation
❑ Must be renewed when
door is renewed.
9 - Window slot seal
❑ Pushed onto flange.
10 - Bolt
❑ 20 Nm
11 - Clamping screw
12 - Cover
13 - Assembly carrier
❑ Removing and installing
⇒ page 187
❑ Window regulator is part
of assembly carrier
❑ Window regulator motor is bolted to assembly carrier from in front.
14 - Bolt
❑ 8 Nm
15 - Loudspeaker
16 - Bolt
17 - Door window
❑ Removing and installing ⇒ page 185
18 - Outer window channel
❑ Pushed onto flange.
2.2.1 Removing
– Remove front door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Trims, insulation; Removing and
installing door trim .
– Disconnect connectors -1- and -2- for exterior mirror and pull
cable out from the door assembly carrier and the door.
– Carefully lever triangular trim out of fastener and swing out.
– Remove bolts and remove mirror.
Note
If the work step cannot be carried out because there is a fault with
the electric window motor, remove motor to slide window down.
2.2.2 Installing
– Insert door window -1- in door. Ensure that door window is
properly located in window channels.
– Press door window -1- into window channel -arrow- and tight‐
en clamping bolts -2- (Qty. 2) (18 Nm).
– Then perform remaining installation in reverse order of remov‐
al.
• Test function before installing door trim.
2.3.1 Removing
– Secure door window against sliding down with adhesive tape.
2.3.2 Installing
WARNING
2.4.1 Removing
– Remove front door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Trims, insulation; Removing and
installing door trim .
– Removing lock cylinder housing ⇒ page 61
Note
If the work step cannot be carried out because there is a fault with
the electric window motor, remove motor to slide window down.
Note
The retaining bracket is not part of the items supplied with the
door lock. Secured to door lock with a bolt and a pop rivet.
2.4.2 Installing
Note
Hooking the operating lever in locks the lock. This prevents „incorrect“ attachment of the Bowden cable later.
Note
– Insert all bolts. Tighten bolts -1- and -2- in the order specified
to specified torque 8 Nm.
– The remaining bolts can be tightened in any sequence.
– Press door window -3- into window channel -arrow- and tight‐
en clamping bolts -4- (Qty. 2) to 10 Nm.
– Then perform remaining installation in reverse order of remov‐
al.
• Test function before installing door trim.
2.5.1 Removing
– Removing exterior mirror
– Carefully raise the window slot seal -2- on the B-pillar -arrow a-
using the removal wedge -3409- .
– Carefully pull the window slot seal -2- evenly -arrow b- by hand
away from the door flange on the front door -1-.
2.5.2 Installing
– Press window slot seal equally by hand onto door flange.
2.6.1 Removing
– Undo the window slot seal as described in the section "Re‐
moving window slot seal" ⇒ page 192 , without removing the
exterior mirror.
– Push window channel -2- far enough to the side to allow you
to reach the bolts. Do not pull window channel out of supports.
– Unscrew bolts -3-.
– Pull trim plate -1- off the door in -direction of arrow-.
2.6.2 Installing
Note
1 - Trim strip
❑ Secured with clips to
door flange.
❑ At same time, secures
window guide on door
flange.
2 - Outer window channel
❑ Pushed onto flange.
3 - C-pillar trim
❑ Removing ⇒ page 204
4 - Window slot seal
❑ Pushed onto flange.
❑ Removing ⇒ page 203
5 - Bolt
❑ Qty. 2.
❑ 3.5 Nm
6 - Door
7 - Bolt
❑ 20 Nm
8 - Insulation
9 - Window slot seal
❑ Pushed onto flange.
10 - Clamping screw
11 - Cover
12 - Bolt
❑ 8 Nm
13 - Assembly carrier
❑ Removing and installing
⇒ page 197
❑ Window regulator is part of assembly carrier
14 - Door window
❑ Removing ⇒ page 195
15 - Window channel trim
16 - B-pillar trim
❑ The adjustment sleeve must be renewed every time trim is adjusted.
❑ Removing ⇒ page 203
17 - Bolt
❑ Qty. 2.
❑ 3.5 Nm
18 - Cross-head screw
3.2.1 Removing
– Remove rear door trim, carrier frame and window frame ⇒
General body repairs, interior; Rep. gr. 70 ; Trims, insulation;
Removing and installing door trim .
– Unclip window channel trim from door.
– Unscrew bolts -2- and remove trim from door frame.
3.2.2 Installing
– Insert door window in door. Ensure that door window is prop‐
erly located in window channels.
– Press door window into window channel -arrow- and tighten
clamping bolts -2- (Qty. 2) (18 Nm).
– Then perform remaining installation in reverse order of remov‐
al.
• Test function before installing door trim.
3.3.1 Removing
– Secure door window against sliding down with adhesive tape.
3.3.2 Installing
WARNING
3.4.1 Removing
– Remove rear door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Trims, insulation; Removing and
installing door trim .
3.4.2 Installing
Note
Hooking the operating lever in locks the lock. This prevents „in‐
correct“ attachment of the Bowden cable later.
– Insert all bolts. Tighten bolts -1- and -2- in the order specified
to specified torque 8 Nm.
– The remaining bolts can be tightened in any sequence.
– Then perform remaining installation in reverse order of remov‐
al.
• Test function before installing door trim.
3.5.1 Removing
Note
3.5.2 Installing
– Installation is carried out in reverse order of removal.
• Test function before installing door trim.
3.6.1 Removing
– Carefully raise the window slot seal -2- on the B-pillar -arrow a-
using the removal wedge -3409- .
– Carefully pull the window slot seal -2- evenly -arrow b- by hand
away from the door flange on the rear door -1-.
3.6.2 Installing
– Press window slot seal equally by hand onto door flange.
Note
66 – Exterior equipment
1 Removing and installing wheel hous‐
ing liner
2 Exterior mirror
2.1 Tools
Special tools and workshop equipment required
♦ Removal lever -80-200-
1 - Mirror mounting
❑ Removing ⇒ page 212
2 - Bolt
❑ Qty. 3
❑ 3 Nm
3 - Insulation
4 - Seal
❑ Self-adhesive.
5 - Cap
❑ Removing ⇒ page 212
6 - Mirror glass
❑ Removing ⇒ page 208
7 - Bolt
❑ Qty. 2
❑ 1 Nm
8 - Assembly part
❑ For turn signal and am‐
bient illumination.
9 - Ambient light
❑ Removing ⇒ page 210
10 - Connector
11 - Side turn signal repeater
❑ Removing ⇒ page 209
12 - Bolt
❑ Qty. 2
❑ 1 Nm
13 - Mirror housing
❑ Removing ⇒ page 208
Note
When doing this repair work, always wear safety goggles and
leather gloves!
2.3.1 Removing
– Protect edge of housing from damage to paintwork e.g. with
fabric-reinforced adhesive tape.
– Press bottom of mirror glass into mirror housing.
– Prise mirror lens -3- out of retainer -2- in the housing with lever
80-200 -arrow 5-.
– Swivel the mirror glass upwards -arrow 6- and detach con‐
nectors -4- on the back of the mirror glass.
2.3.2 Installing
– Connect plug-in contacts to mirror glass.
– Press mirror glass centrally onto bracket in housing.
– Mirror glass engages audibly.
2.4.1 Removing
– Remove mirror glass ⇒ page 208 .
– Fold rear-view mirror forwards to ease removal and installa‐
tion.
2.4.2 Installing
– Installation is carried out in reverse order of removal.
Note
♦ The side turn signal repeaters are fitted with long-life light-
emitting diodes (LEDs) instead of conventional bulbs.
♦ Therefore, changing bulbs is not necessary. In case of dam‐
age, the entire turn signal must be renewed.
2.5.1 Removing
– To remove side turn signal, mirror glass and mirror housing
must be removed, see from ⇒ page 208 .
– Assembly bracket -2- with side turn signal is located on back
of mirror base plate.
– Remove the two bolts -1-.
– Release connectors -3- and pull off.
2.5.2 Installing
– Installation is carried out in reverse order of removal.
2.6.1 Removing
– To remove ambient illumination, mirror glass and mirror hous‐
ing must be removed, see from ⇒ page 209 .
– Release and disconnect connection -1- on the back of mirror
base -2-.
– Detach connector for turn light.
– Remove the two screws -1- from the front of the mirror base.
– Remove assembly part -2- downwards from the mirror base
-arrow-.
2.6.2 Installing
– Installation is carried out in reverse order of removal.
2.7.1 Removing
– Remove mirror housing ⇒ page 208 .
– Release locking hooks for warning lamp for lane change assist
in mirror glass housing -arrow a-.
– Push warning lamp for lane change assist out of mirror hous‐
ing in -direction of arrow b-.
2.7.2 Installing
– Installation is carried out in reverse order of removal.
1 - Exterior mirror
❑ With attachments.
❑ Material: ABS.
2 - Seal
❑ Self-adhesive.
3 - Insulation
4 - Carrier frame
5 - Cover for exterior rear-view
mirror
6 - Bolt
❑ Qty. 3
❑ 3 Nm
7 - Connector
2.9.1 Removing
– Remove front door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Trim, insulation; Door trims .
– Disconnect connectors -1- and -2- for exterior mirror and pull
cable out from the door assembly carrier and the door.
2.9.2 Installing
– Installation is carried out in reverse order of removal.
2.10.1 Removing
– Remove exterior rear-view mirror ⇒ page 212 .
– Pull out insulation -2- from mirror base plate -1-.
2.10.2 Installing
– Installation is carried out in reverse order of removal.
1 - Radiator grille
❑ Material: ASA
2 - Retaining bracket
3 - Bolt
❑ Qty. 5.
❑ 2 Nm
4 - Bolt
❑ Qty. 4.
❑ 4.5 Nm
5 - Company emblem
❑ Clipped into radiator
grille
3.2.1 Removing
– Undo all 9 bolts.
3.2.2 Installing
– Guide radiator grille with retaining brackets from below
-arrow 1- into bonnet.
– Swing down lower part of grille -arrow 2- and centre it.
– First insert upper bolts and then bolts at sides.
Note
The radiator grille is supplied as a complete spare part, except for items -5-, -11- and -12-. However, the items
indicated can be replaced individually.
1 - Bolt
❑ Qty. 6.
❑ 1 Nm
❑ For securing cover part
-2- to radiator grille -4-
2 - Bumper cover insert
❑ Bolted onto radiator
grille -4- with bolts -1-.
3 - Bolt
❑ Qty. 3.
❑ 1 Nm
❑ For securing insert -11-
to radiator grille -4-
4 - Radiator grille
5 - Honeycomb grille
❑ Clipped into radiator
grille -4-
❑ Only fitted on vehicles
without adaptive cruise
control
6 - Trim strip on cover
❑ Left and right.
❑ Clipped into radiator
grille -4-
7 - Top trim strip
❑ Left and right.
❑ Clipped into radiator
grille -4-
8 - Centre trim strip
❑ Left and right.
❑ Clipped into radiator grille -4-
9 - Lower trim strip
❑ Left and right.
❑ Clipped into radiator grille -4-
10 - Decorative trim
❑ Clipped into radiator grille -4-
11 - Insert
❑ Bolted onto radiator grille -4- with bolts -3-.
4.2.1 Removing
4.2.2 Installing
4.3.1 Removing
4.3.2 Installing
– Push VW emblem -1- together with locking hooks -3- into the
insert -2- from the front.
– Turn VW emblem -1- in -direction of arrow- until the locking
hooks -3- latch into place in the insert -2-.
– Push insert together with VW emblem -1- into the radiator grille
-2- from the front until the locking hooks -arrows- latch into
place.
– Screw in bolts -3- on rear of radiator grille -2-.
Specified torque for bolts -3-: 1 Nm.
4.4.1 Removing
4.4.2 Installing
– Place VW emblem -1- together with retaining lugs -arrow a-
into the insert -2-.
– Tip top of VW emblem -1- towards the insert -2- -arrow b- until
the locking hooks on the VW emblem latch into place.
– Push insert together with VW emblem -1- into the radiator grille
-2- from the front until the locking hooks -arrows- latch into
place.
– Screw in bolts -3- on rear of radiator grille -2-.
Specified torque for bolts -3-: 1 Nm.
5 Roof mouldings
1 - Roof moulding
❑ Remove water deflector
⇒ page 228 .
❑ Removing; starting at
windscreen, lever off
with soft plastic wedge.
❑ Do not bend roof mould‐
ing
❑ Installing; place roof
moulding on end of rear
roof channel and press
in from rear to front up to
stop.
2 - Bolt
❑ 9 Nm
3 - Fastening element
❑ For roof rack.
4 - Roof channel
5 - Securing clips
❑ Qty. 7 on each side.
❑ Removing and installing
⇒ page 226
5.2.1 Removing
♦ Push white and black parts of clip against each other as shown
in illustration. Protect painted surfaces from damage.
5.2.2 Installing
♦ Push white and black parts of clip against each other as shown
in illustration. Protect painted surfaces from damage.
1 - Drip channel
2 - Centring hole
❑ When installing, insert
first pop rivet here.
❑ Align drop deflector
along roof side mem‐
bers.
3 - Roof side members
4 - Pop rivet
❑ Qty. 25.
5 - Cover strip
❑ Strip must be levered
out using plastic wedge
on outer side beginning
at C-pillar.
❑ When installing, insert
inside edge first.
6 - Centring cut-out
❑ This cut-out aligns cover
strip on water deflector.
1 - Water deflector
❑ Lift deflector by hand out
of clips beginning at
bonnet and then pull out
of roof moulding.
2 - Pop rivet
❑ 2 per retaining clip.
3 - Retaining clip
❑ Retaining clip can be re‐
newed only after wind‐
screen has been re‐
moved.
4 - A-pillar
5 - Roof moulding
6 - Sealing lip
❑ After installing mould‐
ing, press lip behind
windscreen.
6 Protective strips
– Undo bolts -2- on front and rear ends of sill panel trims.
– Before removing, warm trim strips with hot air blower and pull
off.
– Clean exterior panels with naphtha, treat with silicone remover
and then rub dry.
– Pull protective backing off trim strips -3- and -4- before attach‐
ing. Position the trim strips and press on firmly. Working tem‐
perature about 20 °C.
– Specified torque for bolts: 2 Nm.
Note
Note
Before installing, examine all fastening parts for damage and renew as necessary.
7 Sill trim
– Before removing, warm sill panel trim with hot air blower and
pull off.
– Clean exterior panels with naphtha, treat with silicone remover
and then rub dry.
– Pull protective backing off sill panel moulding -1- and -2- be‐
fore attaching. Attach sill panel trim lightly and then press
forcefully on. Working temperature about 20 °C.
8 Lettering
8.1 Tools
Special tools and workshop equipment required
♦ Hot air blower -V.A.G 1416-
Note
♦ Before removal, warm the lettering with a hot air blower -V.A.G
1416- .
♦ Adhesive remover -D 002 000 10- must be used exclusively.
♦ Ensure that bonding surfaces are free of dust and grease.
♦ The lettering must be bonded in place immediately after clean‐
ing.
♦ Remove protective backing immediately before installation.
Working temperature approx. 21 °C.
1 - Dimension a = 35 mm
❑ From outer edge of rear
lid to lettering.
2 - Dimension b = 38 mm
❑ From lower edge of rear
lid to upper edge of let‐
tering.
3 - Dimension c = 75 mm
❑ From lower edge of rear
lid to lower edge of let‐
tering.
4 - Dimension d = centre line
Centre line through rear lid,
centre line through logo, centre
of lettering.
8. Lettering 237
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
1 - Dimension a = 535 mm
❑ Transfer -dimension a -
from lower edge of wing
to wing.
2 - Dimension b = 48 mm
❑ Use -dimension b- to
check the distance from
the upper edge of the
emblem to the edge of
the wing.
3 - Dimension c = 73 mm
❑ Use -dimension c- to
check the distance from
the lower edge of the
emblem to the edge of
the wing.
1 - Dimension a = 536 mm
❑ Transfer -dimension a -
from lower edge of wing
to wing.
2 - Dimension b = 64 mm
❑ Use -dimension b- to
check the distance from
the upper edge of the
emblem to the edge of
the wing.
3 - Dimension c = 73 mm
❑ Use -dimension c- to
check the distance from
the lower edge of the
emblem to the edge of
the wing.
8. Lettering 239