VW Polo (AW/BZ) Exterior General Body Repairs Workshop Manual

VW Polo (AW/BZ) Exterior General Body Repairs Workshop Manual with high-quality graphics and illustrations.

Format: PDF

Pages: 400

Delivery: The download link will instantly be sent to your email after checkout.

Covered VW Vehicles

• Polo (AW/BZ) series

Repair Group:

• Technical data
• Body – front
• Bonnet, rear lid
• Front doors, door components, central locking
• Rear doors, door components
• Sunroof
• Bumpers
• Glazing
• Exterior equipment

Contents:

• Technical data  
  • Safety information  
  • Safety measures when working on vehicles with a start/stop system  
• Body – front  
  • Lock carrier  
  • Assembly overview – lock carrier  
  • Removing and installing lock carrier  
  • Moving to and back from service position  
  • Wings  
  • Assembly overview – wing  
  • Removing and installing wing  
  • Bulkhead  
  • Assembly overview – plenum chamber bulkhead  
  • Assembly overview – plenum chamber cover  
  • Removing and installing plenum chamber bulkhead  
  • Removing and installing plenum chamber cover  
• Bonnet, rear lid  
  • Bonnet (hood)  
  • Assembly overview – bonnet  
  • Assembly overview – Bowden cable  
  • Removing and installing bonnet  
  • Adjusting bonnet  
  • Removing and installing bonnet lock  
  • Removing and installing bonnet release lever  
  • Removing and installing striker pin  
  • Removing and installing hinges  
  • Renewing hinges  
  • Removing and installing insulation  
  • Removing and installing support rod  
  • Removing and installing Bowden cable  
  • Rear lid  
  • Assembly overview – rear lid  
  • Removing and installing rear lid  
  • Adjusting rear lid  
  • Removing and installing bonnet lock  
  • Removing and installing operating mechanism  
  • Removing and installing hinges  
  • Removing and installing striker pin  
  • Removing and installing rear lid seal  
  • Removing and installing gas strut  
  • Releasing gas from gas strut  
  • Tank flap unit  
  • Assembly overview – tank flap unit  
  • Removing and installing tank flap unit  
  • Removing and installing fuel tank flap  
• Front doors, door components, central locking  
  • Door  
  • Assembly overview – door  
  • Removing and installing inner door seal  
  • Removing and installing outer door seal  
  • Removing and installing door  
  • Adjusting door  
  • Adjusting striker pin  
  • Removing and installing door arrester  
  • Door components  
  • Assembly overview – door components  
  • Assembly overview – window regulator  
  • Assembly overview – door handle and door lock  
  • Removing and installing window regulator motor  
  • Removing and installing window regulator  
  • Removing and installing inner door cover  
  • Removing and installing striker pin  
  • Removing and installing cap on door handle  
  • Removing and installing lock cylinder  
  • Removing and installing door handle  
  • Removing and installing door handle bracket  
  • Removing and installing door lock  
  • Removing and installing window channel  
  • Removing and installing outer window slot seal  
  • Removing and installing inner window slot seal  
  • Central locking  
  • Overview of fitting locations – central locking  
  • Removing and installing ignition key battery  
  • Removing and installing cap on ignition key  
  • Removing and installing tank filler flap locking motor V155  
• Rear doors, door components  
  • Door  
  • Assembly overview – door  
  • Removing and installing door  
  • Adjusting door  
  • Adjusting striker pin  
  • Removing and installing door arrester  
  • Removing and installing inner door seal  
  • Removing and installing outer door seal  
  • Door components  
  • Assembly overview – door components  
  • Assembly overview – window regulator  
  • Assembly overview – door handle and door lock  
  • Removing and installing window regulator motor  
  • Removing and installing window regulator  
  • Removing and installing window crank  
  • Removing and installing inner door cover  
  • Removing and installing striker pin  
  • Removing and installing cap on door handle  
  • Removing and installing door handle  
  • Removing and installing door handle bracket  
  • Removing and installing door lock  
  • Removing and installing window channel  
  • Removing and installing outer window slot seal  
  • Removing and installing inner window slot seal  
• Sunroof  
  • Sliding sunroof  
  • Assembly overview – sliding sunroof  
  • Assembly overview – sunroof seals  
  • Assembly overview – sunroof roller blind  
  • Removing and installing glass panel  
  • Adjusting sunroof panel  
  • Removing and installing front trim for sliding sunroof  
  • Removing and installing wind deflector  
  • Removing and installing sunroof roller blind  
  • Removing and installing sliding sunroof frame  
  • Removing and installing J245 sliding sunroof adjustment control unit  
  • Removing and installing sunroof motor V1  
  • Operating without current  
  • Removing and installing guide plate  
  • Removing and installing sliding sunroof seals  
  • Programming sliding sunroof adjustment control unit J245  
• Bumpers  
  • Bumper, front  
  • Assembly overview – bumper cover  
  • Assembly overview – impact bar  
  • Removing and installing bumper cover  
  • Repairing bumper cover  
  • Installing holder for parking aid sender  
  • Installing retainer for parking aid sender  
  • Bumper, rear  
  • Assembly overview – bumper cover  
  • Assembly overview – impact bar  
  • Removing and installing bumper cover  
  • Removing and installing impact bar  
  • Repairing bumper cover  
  • Installing holder for parking aid sender  
  • Installing retainer for parking aid sender  
• Glazing  
  • Repair notes  
  • Minimum curing periods for bonded windows  
  • Window repair  
  • Installation instructions for bonded windows  
  • Preparing old undamaged windows for fitting  
  • Preparing new windows for installing  
  • Preparing body flange for fitting  
  • Cleaning off excess adhesive  
  • Windscreen  
  • Assembly overview – windscreen  
  • Removing and installing windscreen  
  • Rear windscreen  
  • Assembly overview – rear window  
  • Removing and installing rear window  
  • Side window  
  • Assembly overview – rear side windows  
  • Removing and installing rear side window  
  • Door windows  
  • Assembly overview – front door window  
  • Assembly overview – rear door window  
  • Removing and installing front door window  
  • Removing and installing rear door window  
• Exterior equipment  
  • Radiator grille and front trim  
  • Assembly overview – radiator grille  
  • Removing and installing radiator grille  
  • Spoiler  
  • Assembly overview – spoiler, GTI, R-Line  
  • Removing and installing spoiler, GTI, R-Line  
  • Mouldings, trims, extensions  
  • Assembly overview – side member trim, GTI, R-Line  
  • Removing and installing A-pillar trim  
  • Removing and installing B-pillar trim on door  
  • Removing and installing C-pillar trim on door  
  • Removing and installing entry moulding  
  • Removing and installing side member trim, GTI, R-Line  
  • Noise insulation  
  • Assembly overview – noise insulation  
  • Underbody cladding  
  • Overview of fitting locations – underbody cladding  
  • Removing and installing underbody cladding  
  • Removing and installing centre underbody panels  
  • Removing and installing rear underbody panel  
  • Exterior mirror  
  • Assembly overview – exterior mirror  
  • Removing and installing exterior mirror  
  • Removing and installing mirror glass  
  • Removing and installing mirror adjustment unit  
  • Removing and installing mirror cover  
  • Removing and installing mirror trim  
  • Removing and installing turn signal  
  • Wheel housing liner  
  • Assembly overview – front wheel housing liner  
  • Assembly overview – rear wheel housing liner  
  • Removing and installing front wheel housing liner  
  • Removing and installing rear wheel housing liner  
  • Trim film and protective film  
  • Renewing decorative film and protective film  
  • Decorative film dimensions  
  • Renewing decorative film  
  • Lettering and emblems  
  • Dimensions – lettering and emblems on rear  
  • Dimensions – lettering and emblems on sides  
  • Renewing lettering and badges on sides, GTI, R-Line  
  • Removing and installing lettering and emblems for radiator grille  
  • Renewing lettering and badges at rear  
  • Special add-on parts  
  • Assembly overview – special add-on parts, GTI, R-Line  
  • Towing bracket  
  • Assembly overview – towing bracket  
  • Removing and installing towing bracket  
  • Heat shields  
  • Overview of fitting locations – heat shields  
  • Removing and installing underbody heat shield  
  • Removing and installing heat shield for centre exhaust system  
  • Removing and installing heat shield for rear silencer