Workshop Manual Transporter 2016 25-29

Service
Workshop Manual
Transporter 2016 ➤
General body repairs, exterior
Edition 10.2019
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Service Department. Technical Information

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List of Workshop Manual Repair Groups a ra
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Repair Group
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00 - Technical data
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50 - Body - front
55 - Bonnet, rear lid
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57 - Front doors, door components, central locking
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58 - Rear doors, door components
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60 - Sunroof
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61 - Convertible roof, hardtop, canopy
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63 - Bumpers
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64 - Glazing
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66 - Exterior equipment
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B8056531C

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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Safety precautions when working on a high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Safety precautions when working in vicinity of high-voltage components . . . . . . . . . . . . . . 2
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2 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3 Hazard classification of high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.1 Assembly overview – lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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1.2 Removing and installing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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1.3 Moving to and back from service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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2 Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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3 Plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.1 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.2 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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3.3 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2 Assembly overview - Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.5 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6 Removing and installing bonnet release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.7 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.8 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.9 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.10 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.11 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.12 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5 Removing and installing operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.6 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.8 Removing and installing guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.9 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.10 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.11 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Removing and installing fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Contents i
General body repairs, exterior - Edition 10.2019
1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Assembly overview - door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.5 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.6 Greasing new door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.7 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.8 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4 Assembly overview - window channels and window slot (aperture) seals . . . . . . . . . . . . . . 74
2.5 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.6 Removing and installing window crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.7 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.8 Removing and installing lock cylinder . . .n.A.G.. V. o.lk.sw . a. g.e.n .A. . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.9 Removing and installing door handle w. . . . . . . . . . . . . . . . . o. e.s.n.ot. . . . . . . . . . . . . . . . . . . . . 80
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2.10 Removing and installing doorislock ed
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2.11 Removing and installing mounting ut
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2.12 Removing and installingssstriker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . 85
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3 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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3.1 Overview of fitting locations - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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3.2 Assembly overview - ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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3.3 Removing and installing ignition key battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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1 Sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1 Assembly overview – sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.2 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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1.3 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.4 Removing and installing sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.5 Adjusting sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1.7 Removing and installing lower roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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1.9 Removing and installing hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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1.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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1.11 Removing and installing sliding door remote release mechanism . . . . . . . . . . . . . . . . . . . . 117
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1.12 Removing and installing contact module and contact strip . . . . . . . . . . . . . . . . . . . . . . . . 119
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1.13 Removing and installing lock cylinder and outer door handle . . . . . . . . . . . . . . . . . . . . . . 121
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1.14 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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1.15 Removing and installing interior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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1.16 Removing and installing upper guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.17 Removing and installing middle guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 Electrically operated sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.1 Assembly overview - electric sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.2 Removing and installing outer door seal with roll-back function . . . . . . . . . . . . . . . . . . . . . . 134
2.3 Removing and installing sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.4 Removing and installing striker pin with power latching motor . . . . . . . . . . . . . . . . . . . . . . 137
2.6 Removing and installing motor to open right sliding door V323 . . . . . . . . . . . . . . . . . . . . 139
2.7 Removing and installing guide rail with roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.8 Removing and installing upper guide rail with reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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2.9 Removing and
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... 146
2.10 Removing and installing lower roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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2.11 Removing and installing right electric sliding door sender unit G481 . . . . . . . . . . . . . . . . 148
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3 Sliding door - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3.1 Assembly overview – sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3.2 Removing and installing inner door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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3.3 Renewing pre-seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.4 Removing and installing additional lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.5 Removing and installing manual release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.6 Removing and installing centre stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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3.7 Removing and installing guide wedge - wedge guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4 Cab door - double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.1 Assembly overview - cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

4.2 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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4.3 Removing and installing inner door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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4.4 Removing and installing cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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4.5 Adjusting cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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4.7 Removing and installing door hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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4.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.9 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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4.10 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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4.11 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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4.12 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.13 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5 Wing doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.1 Assembly overview - wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.2 Assembly overview - door arrester with opening angle of 250° . . . . . . . . . . . . . . . . . . . . . . 177
5.3 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.4 Removing and installing wing door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.5 Removing and installing inner seal of wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.6 Removing and installing wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.7 Adjusting wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.8 Removing and installing upper striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.9 Removing and installing lower striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.10 Replacing wing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.11 Removing and installing wing door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.13 Installing stop in wing door for door arrester with opening angle of 250° . . . . . . . . . . . . . . 195
5.14 Removing and installing wing door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.15 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.16 Removing and installing childproof lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.17 Removing and installing latch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.18 Removing and installing interior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.19 Removing and installing exterior door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.20 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.21 Removing and installing light strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5.22 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1 Sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.1 Assembly overview - sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.2 Removing and installing glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.3 Adjusting sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.4 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Contents iii
1.5 Removing and installing wind deflector

. Volkswagen.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
gen AG
1.6 Removing and installing
o lkswasliding headliner . d.o.es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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1.7 Removing andiseinstalling
d b sliding/tilting sunroof drive ua.ra.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
r te
1.8 Adjusting drive
ut
ho for sliding/tilting sunroof (zero position) .e.or. . . . . . . . . . . . . . . . . . . . . . . . . . 216
a a
1.9 Removingss and installing tilt mechanism for sliding sunroof .c . . . . . . . . . . . . . . . . . . . . . . . 217
ce
le
1.10 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

un
pt
an
d
1.11 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

itte
y li
rm
ab
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
pe
ility
ot
2.1 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
wit
, is n
h re
hole
61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
spec
es, in part or in w
1 Convertible top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
t to the co
1.1 Assembly overview - canopy frame with canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
rrectness of i
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
l purpos
1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
nform
ercia
1.2 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

m
satelettronica
a
com
t
1.3 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
ion in
r
2 Bumper, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

te o
thi
s
iva
2.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
do
r
rp
cum
2.2 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
fo
en
ng
2.3 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

t.
yi Co
op py
2.4 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
t. C rig
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yri
2.5 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
p by
co Vo
by lksw
cted agen
Prote AG.
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.1 Minimum curing periods for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.3 Installation instructions for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.5 Preparing new windows for installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.1 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3 Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3.1 Assembly overview - side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3.2 Removing and installing rear side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4 Sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.1 Assembly overview - sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.2 Removing sliding window for sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.3 Removing broken sliding window for sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.4 Installing sliding window for sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.5 Checking and observing new sliding window prior to installation . . . . . . . . . . . . . . . . . . . . 286
4.6 Removing and installing movable section of sliding window . . . . . . . . . . . . . . . . . . . . . . . . 287
4.7 Removing undamaged sliding window for side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.8 Removing broken sliding window for side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.9 Installing sliding window for side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5 Rear windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.2 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
iv Contents
6 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

6.1 Removing and installing front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
6.2 Adjusting front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

1 Radiator grille and front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
2 Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
2.1 Removing and installing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.1 Assembly overview - B-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.2 Assembly overview - guide rail
olksw.a.ge . n. A. G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
en AG. V
w-agheat d
3.3 Assembly overview olks shield . . . . . .oe. s.n.ot.g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
yV ua
3.4 Removingisand ed installing trim strip . . . . . . . . . . . r.an. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
te
319
r
3.5 Removing
aut
h and installing side member trim . . . . . . .e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . .
o
ra 326
3.6 Removing
ss and installing roller guide trim . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
ce
e
nl
3.7 Removing and installing wing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
pt
du
an
itte
3.8 Removing and installing guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
satelettronica
y li
erm
ab
3.9 Renewing roof strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
ility
ot p
3.10 Removing and installing underbody heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
wit
, is n
h re
4 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
hole
spec
4.1 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
es, in part or in w
t to the co
4.2 Removing and installing noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
5 Underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
5.1 Assembly overview - underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
rrectness of i
5.2 Removing and installing underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
l purpos
6 Trim film and protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

6.1 Renewing decorative film and protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
nf
ercia
7 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

rm
m
atio
7.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

om
n in
c
7.2 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

or
thi
e
7.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

t
sd
iva
o
r
7.4 Removing and installing mirror trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

rp
cu
o
m
f
7.5 Removing and installing mirror cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

en
ng
t.
yi Co
op
8 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
C py
t. rig
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8.1 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
yri
376
p by
co Vo
by lksw
8.2 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
377
8.3 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
8.4 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
9 Lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
9.1 Assembly overview - lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
9.2 Dimensions - lettering and emblems on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
9.3 Renewing lettering and badges at rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
9.4 Renewing lettering and badges on sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
9.5 Removing and installing lettering and emblems for radiator grille . . . . . . . . . . . . . . . . . . . . 393
10 Special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
10.1 Assembly overview – special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
11 Load floor body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
11.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
11.2 Assembly overview - dropside body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
11.3 Assembly overview - load floor and side boards/tail board . . . . . . . . . . . . . . . . . . . . . . . . 397
11.4 Assembly overview - skid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
11.5 Assembly overview - rear wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Contents v
11.6 Assembly overview - tank trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

12 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
12.1 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
12.2 Removing and installing towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
13 Spare wheel bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
13.1 Assembly overview - spare wheel bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
14 Mudflap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
14.1 Assembly overview - mudflap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
satelettronica
AG. Volkswagen AG d
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urposes, in part or in wh
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Contents
agen
Prote AG.
00 – Technical data
1 Safety information
(VRL013548; Edition 10.2019)
⇒ “1.1 Safety precautions when working on a high-voltage sys‐
tem”, page 1
⇒ “1.2 Safety precautions when working in vicinity of high-voltage
components”, page 2
1.1 Safety precautions when working on a high-voltage system

Danger to life due to high voltage
The high-voltage system is under high voltage. Severe or fatal
injury due to electric shock.
– Persons with life-preserving or other electronic medical devi‐
ces in or on their body must not perform any work on the high-
voltage system. Such medical devices include internal anal‐
gesic pumps, implanted defibrillators, pacemakers, insulin
satelettronica
pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified technician.
AG. Volkswagen AG d
agen oes
olksw not
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Risk of injury from unexpected
autho
engine/motor start eo
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ss c
On electric and hybrid vehicles, the operational readiness of the
ce
le
un
vehicle is difficult to detect. There is a risk of parts of the body

pt
an
d
itte
becoming trapped or drawn in.

y li
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ab
– Switch off ignition.

ility
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is n
– Always store the ignition key outside the vehicle.

h re
ole,
spec
t to the co
Risk of damage to high-voltage cables

rrectne
Improper handling of high-voltage cables or high-voltage connec‐

tors may result in damage to their insulation.
ss o
– Never support yourself on high-voltage cables or high-voltage

cial p
f in
connectors.
form
mer
atio
– Never rest tools on high-voltage cables or high-voltage con‐

om
nectors.
n
c
i
or
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– Never kink or sharply bend high-voltage cables.

t
sd
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– Always connect high-voltage connectors according to coding.

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Risk of injury from activated stationary air conditioning Prote AG.
On electric and hybrid vehicles with active stationary air condi‐

tioning, the stationary air conditioning could switch on uninten‐
tionally. Risk of limbs becoming trapped or drawn in by the
radiator fan starting automatically.
– Deactivate the stationary air conditioning.
1. Safety information 1
1.2 Safety precautions when working in vicinity of high-voltage components

Danger to life due to high voltage
The high-voltage system is under high voltage. Damage to high-
voltage components will result in severe or fatal injury from elec‐
tric shock.
– Perform visual check of high-voltage components and high-
voltage cables.
– Never use cutting or forming tools, or any other sharp-edged
tools.
olkswagen AG
en AG. V
– Never use heat sources such ksas
wagwelding, brazing, soldering,
does
not
Vol
hot air or thermal bonding
d b equipment.
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es, in part or in w
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nf
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2 Rep. gr.00 - Technical data

2 Repair notes
⇒ “2.1 General information”, page 3
2.1 General information

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and for fault finding, first read event mem‐
ory.
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not burn and cause damage to the
lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces
the risk of a fire in a collision thanks to the fuel pump being
switched off via the fuel pump relay.
♦ The system also improves the starting characteristics of the
engine. When the driver door is opened, the fuel pump is ac‐
tivated for 2 seconds to develop pressure
olks
wage in the fuel system. es n
satelettronica
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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a
com
tion in
r
te o
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2. Repair notes 3
AG. Volkswagen AG d
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3 Hazard classification of high-voltage by gu
d ara
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or
system h eo
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WARNING
an
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The vehicle’s high-voltage system and high-voltage battery are
ot
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dangerous and can cause burns or other injuries and even lead
, is n
h re
to a fatal electric shock.
hole
spec
• Any work on the high-voltage system, or on systems which
es, in part or in w
t to the co
could be indirectly affected by it, may only be carried out
by properly trained and qualified expert personnel.
• If there are any questions or there is any doubt regarding
rrectness of i
the terms “high-voltage technician” or “high-voltage ex‐
pert”, likewise if there are any questions about the high-
l purpos
voltage system, the responsible importer must be contac‐

ted before starting any work.
nform
ercia
• Any repair work must be performed in accordance with

m
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applicable laws and regulations, approved engineering
com
tio
practices, any relevant accident prevention regulations (in
n in
satelettronica
r
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Germany, including but not limited to the BGI/GUV-I 8686
thi
s
– Training for work on vehicles with high-voltage systems),
iva
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as well as this workshop manual.

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This vehicle is electrified by ABT e-Line.
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All relevant repair and maintenance information regarding modi‐
lksw
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Prote
fications by ABT e-Line are available in the Electronic Service
AG.
Information System (ElsaPro), section “Superstructures and

modifications”. It can also be obtained from ABT e-Line.
4 Rep. gr.00 - Technical data

50 – Body - front
1 Lock carrier AG. Volkswagen AG d
agen oes
⇒ “1.1 Assembly overview – lock carrier”, page 5 olksw not
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⇒ “1.2 Removing and installing lock carrier”, page thori6 eo
au ra
⇒ “1.3 Moving to and back from service position”,
ss page 8 c
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1.1 Assembly overview – lock carrier
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Note
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♦ The lock carrier is a safety-relevant component. It must not be repaired for this reason.
es, in part or in w
t to the co
♦ If damaged, the lock carrier must be renewed.
rrectness of i
1 - Lock carrier
satelettronica
l purpos
❑ Removing and installing

lock carrier
⇒ page 6
nform
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❑ Moving in and out of

m
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service position
tion in
⇒ page 8
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2 - Bolts
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❑ Renew after removal
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❑ Left and right
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3 - Washer
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❑ Qty. 4
4 - Bolts
❑ Qty. 2 each on left and
right
❑ 9 Nm
5 - Deformation element
6 - Lower baffle plate
7 - Bumper carrier
8 - Bolts
right
❑ 20 Nm
9 - Clip
❑ Qty. 3
10 - Ambient temperature sen‐
sor - G17-
⇒ Heating, air conditioning system; Rep. gr. 80 ; Other control components; Removing and installing
ambient temperature sensor - G17-
11 - Mounting bracket
❑ Left and right
1. Lock carrier 5
12 - Bolts
❑ Qty. 2 each on left and right
❑ 6 Nm +90°
13 - Bolts
❑ Qty. 2 each on left and right
❑ 6 Nm +90°
lkswage es n
1.2 Removing and installing lock carrier
o ot g
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Special tools and workshop
auth
equipment required or
ac
ss
♦ Guide pins - T10228-
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♦ Torque wrench - V.A.G 1331-

inform
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6 Rep. gr.50 - Body - front

AG. Volkswagen AG d
agen oes
olksw not
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tho e oTransporter
2016 ➤
au ra
ss General body repairs, exterior - Edition 10.2019
c
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Removing
– Move lock carrier -1- to service position ⇒ page 8 .
– Unclip Bowden cable for bonnet lock ⇒ page 26 .
– Disconnect any electrical connectors.
– Drain coolant and disconnect coolant lines ⇒ Rep. gr. 19 ;
Cooling system, coolant; Draining and filling coolant .
– Disconnect lines for condenser ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; Disconnecting refrigerant
lines from and connecting to condenser .
– Further dismantling requires the assistance of a second me‐
chanic.
– Screw in guide pins - T10228- on left and right longitudinal
member.
– Lift out lock carrier -1-.
WARNING
Do not start the engine if the air conditioning system and/or the
coolant system lines are disconnected.
1. Lock carrier 7
Note
♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.
Installing
Install in reverse order of removal, observing the following:
agen
AG. Volkswagen AG d
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olks ot g
– Move back from service position ⇒ page 10e.d by V ua
ran
is tee
or
1.3 Moving to and back fromau
th
service posi‐ or
ac
ss
tion
ce
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nl
pt
du
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Special tools and workshop equipment required
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♦ Guide pins - T10228-
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satelettronica
AG. Volkswagen AG d
agen oes
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Moving to service position
l purpos
– Gas struts must be removed on vehicles with gas struts

⇒ page 31 .
nform
ercia
– Brace the bonnet open.

m
at
om
ion
c
– Remove front bumper cover ⇒ page 230 .

in t
or
his
ate
– Remove coolant reservoir, and lay it to one side ⇒ Rep. gr.

do
riv
19 ; Cooling system, coolant; Coolant hose schematic dia‐

p
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for
gram .
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– Remove filler pipe for washer fluid reservoir ⇒ Electrical sys‐
C py
t. rig
gh
tem; Rep. gr. 92 ; Windscreen washer system; Removing and
ht
pyri by
Vo
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installing washer fluid reservoir . by c lksw
cted agen
Prote AG.
– On vehicles whose charge air cooler is connected to the lock
carrier, detach pressure hoses ⇒ Rep. gr. 21 ; Charge air
system; Assembly overview – charge-air hose connections .
– Unscrew bolts -4- on left and right.
– Screw guide pins - T10228- into left and right longitudinal
member (Qty. 2 into each).
1. Lock carrier 9
swage es n
– On vehicles whose charge air cooler is connected to the block yV
olk ot g
ua
carrier, the pressure hoses need to be detached. ir se
d ran
tee
t ho
or
– Lock carrier can be pulled approx. 15 cm forwards
ss
au
in ac
-direction of arrow- on special tool -1- guide pins - T10228- .
ce
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– Move hoses and lines in the same direction at the same time.
d
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Moving from service position
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Move back from service position in the reverse order observing
, is n
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the following:
hole
spec
– Push lock carrier together with add-on parts -1- on the guide
es, in part or in w
t to the co
pins - T10228- and onto the longitudinal member.
– Centre the lock carrier on the longitudinal members between
the wings ⇒ Body Repairs; Rep. gr. 00 ; Panel gaps/shut lines;
rrectness of i
Body - front .
l purpos
If present, calibrate adaptive cruise control ⇒ Running gear,

axles, steering; Rep. gr. 44 ; Adaptive cruise control; Calibrating
nform
ercia
adaptive cruise control .

m
Specified torques
a
com
tion in
♦ ⇒ “1.1 Assembly overview – lock carrier”, page 5
r
satelettronica
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2 Wings
⇒ “2.1 Assembly overview - wing”, page 11
⇒ “2.2 Removing and installing wing”, page 11
⇒ “2.2.2 Removing and installing guide bracket”, page 13
2.1 Assembly overview - wing
Note
The illustrations show the left-hand side. The right side is analogous.
1 - Wings
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AG. Volkswagen AG d
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⇒ page 11 y Volksw not
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2 - Bolts horis tee
t or
❑ Qty. au
ss 3, A-pillar
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❑ 4 Nm ce
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nl
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3 - Guide profile y li
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⇒ page 13
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4 - Bolts
hole
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❑ Qty. 2
es, in part or in w
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❑ 2 Nm
5 - Bolts
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❑ Qty. 3, wheel housing

l purpos
❑ 4 Nm
nform
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c
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Prote AG.
2.2 Removing and installing wing
2.2.1 Removing and installing wing

2. Wings 11
Note
The removal and installation procedure

gen AG
.is
Vofor
lkswthe
agenleft
AG dside. Removal and installation of the right side is similar.
wa oes
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Removing

– Remove headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐

lights; Removing and installing headlights . . Volkswagen AG
gen AG does a
not lksw
– Remove wheel housing liner d⇒bypage
Vo 377 . gu
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– Remove turn signal repeaters
utho ⇒ Electrical system; Rep. gr. eo
ra
94 ; Turn signal repeaters;
ss a Removing and installing turn signal c
repeater .
ce
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– Remove wing triangular cover ⇒ page 330 .
itte
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– Unscrew bolts -2-.
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– Remove wing -1-.
Installing
rrectness of i
l purpos
– Ensure that gaps and shut lines are parallel and specified di‐
mensions are maintained ⇒ Body Repairs; Rep. gr. 00 ; Panel
gaps/shut lines; Body - front .
nform
ercia
satelettronica
m
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com
tio
Note
n in
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Before installing guide -4- check for damage and renew if necessary.
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♦ ⇒ “2.1 Assembly overview - wing”, page 11
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2.2.2 Removing and installing guide bracket
by lksw
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Prote AG.

Note
Removal and installation are described only for the left wing
bracket. Removal and installation of the right wing bracket are
similar.
Removing
2. Wings 13

– Remove guide -1-.
Installing
– Fit rib behind wing.
– Swing in guide bracket -1-, and carefully push clips into holes
in wing until they can be heard to engage.
Specified torques
♦ ⇒ “2.1 Assembly overview - wing”, page 11
satelettronica
AG. Volkswagen AG d
agen oes
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3 Plenum chamber bulkhead

⇒ “3.1 Assembly overview - plenum chamber bulkhead”,
page 15
⇒ “3.2 Assembly overview - plenum chamber cover”, page 17
⇒ “3.3 Removing and installing plenum chamber cover”,
page 18
3.1 Assembly overview - plenum chamber

bulkhead
⇒ “3.1.1 Assembly overview - plenum chamber bulkhead”,
page 15
⇒ “3.1.2 Assembly overview - bulkhead, bulkhead cover”,
page 16
3.1.1 Assembly overview - plenum chamber bulkhead
Note
satelettronica
Open holes are to be sealed with aluminium laminated insulation (self-adhesive) ⇒ Electronic parts catalogue
(ETKA) .
1 - Plenum chamber bulkhead

❑ Components and add-
on parts removed
2 - Bolts
❑ Qty. 9
❑ 20 Nm +90°
AG. Volkswagen AG d
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3 - Bolts olksw not
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❑ Renew after removal orise nte
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Prote AG.
3. Plenum chamber bulkhead
❑ 20 Nm +90°
3.1.2 Assembly overview - bulkhead, bulkhead cover
1 - Seal
❑ Plenum chamber cover
2 - Seal
❑ Web plate
❑ When installing bulk‐
head, ensure seal is cor‐
rectly seated
3 - Bolt
❑ Qty. 2
❑ 8 Nm
4 - Cover
❑ Right
satelettronica
❑ Removing:
❑ Pull off seal from right of
plenum chamber.
5 - Cover
❑ Left
❑ Removing:
❑ Remove plenum cham‐ n AG. Volkswagen AG do
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⇒ page 18 ir se
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6 - Bolt ss
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❑ Qty. 2
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❑ 8 Nm
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7 - Seal
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❑ When installing bulk‐

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3.2 Assembly overview - plenum chamber cover
1 - Plenum chamber cover

⇒ page 18
2 - Seal
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3. Plenum chamber bulkhead 17

3.3 Removing and installing plenum chamber cover
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screen wiper system; Removing and installing wiper arms .

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– Pull seal -1- on plenum chamber off entire length of plenum

chamber bulkhead.
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– Unclip guide -3- from plenum chamber cover -2-.

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WARNING
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The plenum chamber cover must not be levered off with a tool
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Rep. gr.50 - Body - front
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3. Plenum chamber bulkhead 19

55 – Bonnet, rear lid

1 Bonnet
⇒ “1.1 Assembly overview - bonnet”, page 20
⇒ “1.2 Assembly overview - Bowden cable”, page 22
⇒ “1.3 Removing and installing bonnet”, page 22
⇒ “1.4 Adjusting bonnet”, page 23
⇒ “1.5 Removing and installing bonnet lock”, page 26
⇒ “1.6 Removing and installing bonnet release lever”, page 28
⇒ “1.7 Removing and installing striker pin”, page 29
⇒ “1.8 Removing and installing hinges”, page 29
⇒ “1.9 Removing and installing insulation”, page 30
⇒ “1.10 Removing and installing gas strut”, page 31
⇒ “1.11 Releasing gas from gas strut”, page 32
satelettronica
⇒ “1.12 Removing and installing Bowden cable”, page 32
1.1 Assembly overview - bonnet
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20 Rep. gr.55 - Bonnet, rear lid

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General body nte repairs, exterior - Edition 10.2019
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1 - Bonnet ss c
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3 - Striker
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⇒ page 29
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⇒ page 30 Prote AG.
6 - Bolts
❑ For securing bonnet
❑ Qty. 2 on each side
❑ 20 Nm
7 - Hinge
⇒ page 29
8 - Bolts
❑ For securing hinge
❑ 20 Nm
9 - Bowden cable
❑ Removing and installing ⇒ page 32
10 - Bonnet lock
11 - Bolts
❑ Qty. 3
❑ 9 Nm
12 - Gas strut
1. Bonnet 21
1.2 Assembly overview - Bowden cable
1 - Expansion nut
❑ Qty. 3
3 - Bolts
❑ Qty. 3
❑ 2 Nm
4 - Bellows
5 - Operating lever
⇒ page 28
6 - Bowden cable
❑ From mounting bracket
to bonnet lock
⇒ page 32
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7 - Bonnet lock
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 26 lkswage es n
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Removing
– Remove spray jets -4- ⇒ Electrical system; Rep. gr. 92 ; Win‐
dow washer system; Removing and installing spray jets .
– Loosen bolts -3- on left and right (do not unscrew completely).
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– Adjust bonnet -1- if it has been renewed ⇒ page 23 .
Specified torques
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♦ ⇒ “1.1 Assembly overview - bonnet”, page 20
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1.4 Adjusting bonnet
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♦ Setting gauge - 3371-
1. Bonnet 23
Note
♦ The vehicle must be positioned on its wheels for the basic ad‐
justment of the bonnet.
♦ The adjusting buffers -2- on the left and right sides cannot be
used to adjust the rear lid. They have the function of stabilising
and damping the bonnet ⇒ page 25 .
♦ The bonnet is adjusted correctly if the gaps/shut lines are even
all around, the door is not too deep or does not protrude and
all contours align when the is door closed.
♦ The bonnet must engage into the lid lock without excessive
force.
♦ To check or adjust the gaps/shut lines ⇒ Body Repairs; Rep.
gr. 00 ; Gaps/shut lines; Body - front .
– Remove striker pin -1- ⇒ page 29 .

– Gas struts must be removed on vehicles with gas struts
⇒ page 31 .
satelettronica
– Adjust hinges -3- ⇒ page 26 .
– Bonnet can still be adjusted slightly at bonnet lock -4-
⇒ page 24 .
– After bonnet has been adjusted, striker pin -1- can be rein‐
stalled and adjusted ⇒ page 24 .
Adjusting striker pin
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– Loosen bolts -2-.

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– Striker pin -1- can now be adjusted on bonnet in lateral direc‐

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tion via elongated holes -arrows-.

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Adjusting lid lock

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– Loosen bolts -2- to allow bonnet to be corrected or adjusted

slightly.
– Loosen bolts -2- to adjust bonnet lock -1- relative to bonnet
laterally -arrow a- and vertically -arrows b-.
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– Checking gaps/shut lines ⇒ Body Repairs; Rep. gr. ir se 00 ; Panel nte
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– Screw in all 4 adjusting buffers to stop.

– Close bonnet.
– The gap between the bonnet and wing is adjusted according
to the gap plan by screwing outer adjusting buffers -1- in and
out in -direction of arrow- with the bonnet slightly raised.
– Open bonnet.
– If necessary, loosen bolts on bonnet lock.
1. Bonnet 25
– Adjust gap via bonnet lock as well ⇒ page 24 .

– Adjust inner adjusting buffers -1- so that bonnet rests on radi‐
ator grille, and unscrew them by 90°.
Adjusting hinges
– By loosening bolts -2- on left and right bonnet hinges -1-, the
bonnet can be adjusted in longitudinal direction -arrows-.
– After adjusting, carry out corrosion protection measures on
bonnet hinges -1- and bolts -2-.
– Make sure that gaps are uniform ⇒ Body Repairs; Rep. gr.
00 ; Gaps/shut lines; Body - front .
– If necessary, readjust adjustment buffers ⇒ page 25 .
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Removing
– Open bonnet.
– Remove bolts -2- from lock carrier.
– Remove bonnet lock -1- from lock carrier -arrow c-.
– Unclip sleeve on bonnet lock, and detach Bowden cable -4-
-arrow a-.
– Unclip microswitch -3- from bonnet lock -1- -arrow b-.
Installing
Specified torques
1. Bonnet 27
1.6 Removing and installing bonnet release lever

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Removing
– Slightly pull operating lever -3-, and unlock bonnet.
– Insert a small screwdriver in gap between release lever -3- and
retaining clip -2-.
– Lever retaining clip -2- out of release lever -3- -arrow a-.
– Pull release lever off mounting bracket -3- -arrow b-.
For further work on mounting bracket -1-, remove lower A-pillar
trim ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, interior;
Removing and installing A-pillar trim .
Installing
• Lower A-pillar trim is installed.
– Push retaining clip -2- into release lever -3-.
– Press release lever -3- onto mounting bracket -1-.
Before closing bonnet, check function of release lever and Bow‐
den cable.

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– Remove striker pin -1- from bonnet.
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Specified torques
1.8 Removing and installing hinges

Removing
Note
The removal and installation procedure is for the left side. Re‐
moval and installation of the right side is similar.
– Remove plenum chamber cover on left hinge ⇒ page 18 .

– Remove gas strut on right bonnet hinge ⇒ page 31 .
1. Bonnet 29
Note
Make sure that the bonnet is secured or supported accordingly.
Further removal is only possible with the assistance of a second

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satelettronica
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1.9 Removing and installing insulation
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Removing
– Lever clips -2- (qty. 9) out of insulation -1- using removal lever
- 80-200- .
– Remove insulation -1-.
Installing
– When installing insulation -2-, ensure that clips -1- are inserted
with short side upward.
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1.10 Removing and installing gas strut
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1. Bonnet 31
Removing
– Open and support bonnet.
WARNING
Proceed with care if gas strut is reused. Do not lever spring clip
completely out of ball socket, as it will otherwise be damaged.
Gas strut will spring out of mounting, causing damage or injury
to operator.
– Position a small screwdriver -3- beneath spring clip -2-.

– Raise spring clip -2- in such a way that it can be moved over
ball socket -arrow a-.
– Pull off gas strut -1- from ball-head pin -4- -arrow b-.
After removing gas strut -1-, slide spring clip -2- back immediately.
– When the gas strut is disposed, gas needs to be released from
gas strut ⇒ page 32 .
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1.11 Releasing gas from gas strut pt

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WARNING
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Wear protective goggles when sawing.

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Cover area of saw cut with a cloth.

Feed oil and cleaning clothes into existing method of disposal.
rrectness of i
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– Saw open strut cylinder in first third of total cylinder length,

starting from the reference edge on the piston rod side.
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1.12 Removing and installing Bowden cable
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Removing
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– Open bonnet.
s
– Remove release lever ⇒ page 28 .

s o
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– Unclip sleeve -2- on bonnet lock.

nform
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– Slightly pull sleeve -2- off bonnet lock -1- -arrow a-.
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– Detach cable -4- -arrow b-.

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– Unclip Bowden cable -4- from mounting bracket -3- -arrow c-.
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Install in reverse order of removal, observing the following: Prote
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• Before closing bonnet, check function of release lever and

Bowden cable.
1. Bonnet 33
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⇒ “2.5 Removing and installing operating mechanism”,
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⇒ “2.6 Removing and installing hinges”, page 46
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⇒ “2.8 Removing and installing guide”, page 50
⇒ “2.9 Removing and installing rear lid seal”, page 50
ss o
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⇒ “2.10 Removing and installing gas strut”, page 51
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⇒ “2.11 Releasing gas from gas strut”, page 54
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2.1 Assembly overview - rear lid

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1 - Rear lid
⇒ page 37
2 - Bonnet lock
3 - Bolts
❑ Qty. 2
❑ 20 Nm
4 - Operating mechanism
⇒ page 42
5 - Bolts
❑ Qty. 4
❑ 8 Nm
6 - Hinges
❑ Left and right
satelettronica
⇒ page 46
7 - Bolts
❑ Qty. 2
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⇒ page 42
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10 - Gas strut/ motor 1 for rear lid - V444- / -V445-
h re
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❑ Removing and installing gas strut ⇒ page 51
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❑ Releasing gas from gas strut ⇒ page 54 .
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❑ Removing and installing motor 1 for rear lid ⇒ page 51
11 - Bracket with ball-head pin rrectness of i
❑ On side panel
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12 - Bolts
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❑ 20 Nm
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13 - Rear lid seal

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14 - Centring pin
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15 - Bolts by c lksw
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Prote AG.
❑ Qty. 2
❑ 8 Nm
16 - Striker
2. Rear lid 35
AG. Volkswagen AG d
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Transporter 2016 ➤ d by ara
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General body repairs, exterior - Editionut 10.2019
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17 - Bolts
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❑ Qty. 2
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18 - Guide wedge
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19 - Bolts
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❑ Qty. 2
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❑ 4 Nm
20 - Bolt
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❑ 15 Nm
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The right side is shown. The left side is similar. op Vo
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1 - Rear lid
⇒ page 37
2 - Hinges
❑ Left and right
⇒ page 46
3 - Seal
❑ Left and right
4 - Reinforcement plate
❑ Left and right
5 - Nuts
❑ Qty. 2

❑ 30 Nm +90°
2.2 Removing and installing rear lid

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Removing
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– sRemove rear lid trim ⇒ General body repairs, interior; Rep.
ce
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gr. 70 ; Luggage compartment trims; Removing and installing

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lower rear lid trim .

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– Disconnect connectors from existing electrical components

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gr. 92 ; Rear window washer system; Assembly overview -

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hole
rear window washer system .

spec
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– Disconnect connector of high-level brake light ⇒ Electrical

t to the co
system; Rep. gr. 94 ; High-level brake light; Removing and

installing high-level brake light .
rrectness of i
– Disconnect connector on rear lid lock.

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– Remove stop buffer.

– Guide cables and hoses -4- through opening in rear lid -1-.
nform
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– Loosen bolts -2- a few turns on left and right hinges.

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Further dismantling requires the assistance of a second mechan‐

on
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or
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– Remove gas struts -3- on left and right of rear lid -1-
do
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⇒ page 51 .
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– Remove rear lid -1-.
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Prote AG.

– Adjust rear lid -1- ⇒ page 38 .
Note
Carry out corrosion protection measures on bonnet hinge and

bolts after assembly and adjustment work.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear lid”, page 34
2. Rear lid 37
2.3 Adjusting rear lid


AG. Volkswagen AG d
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The vehicle must be standing on its wheels to enable the rear lid
-1- to be adjusted.
The basic setting of the rear lid -1- is carried out by adjusting the
rrectness of i
hinges -4- ⇒ page 38 .
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Rear lid -1- is adjusted via the striker pin -6- on the lock carrier
⇒ page 39 .
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The rear lid -1- must engage in the striker pin -6- without exces‐
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Adjusting hinges
– Remove rear roof trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Roof trims; Removing and installing moulded head‐
liner .
– Remove rear lid gas strut ⇒ page 51 .

– Loosen bolts -2- and nuts -3- in roof side member opening at
rear (do not unscrew them completely).
Note
The nuts -3- can only be loosened with a “long-shaft socket”, as

the guide pins of the hinge -1- are too long.
– Align rear lid uniformly according to outer contours -arrows- on
satelettronica
left and right with the help of a second mechanic.
Adjusting guide AG. Volkswagen AG d
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– Remove bumper by cover end pieces ⇒ page 230 . guar
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– Loosen bolts -3- (do not unscrew them completely) until cen‐
es, in part or in w
tring pin -2- is free to move on left and right.

t to the co
– Close rear lid.

– Align centring pin -2- with guide wedge -1-, and tighten bolts
rrectness of i
-3-.
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– Align centring pin -2- with guide wedge -1-, and tighten bolt
-4-.
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2. Rear lid 39
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Transportery V2016olks ➤ ot g
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General ir sebody repairs, exterior - Edition 10.2019ante
d r
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– Loosenssbolts -2- (do not remove), and move striker pin -1- c
within over-size holes.
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– Move striker pin -1- into upper position -arrow - and lightly
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tighten the bolts -2-.
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spec
Adjusting adjusting buffer
es, in part or in w
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The gaps between rear lid and body must have already been ad‐
justed. The adjusting buffer -1- is not used for adjusting the gaps.
nform
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– Insert adjusting buffer -1- to stop into shaped hole (rear lid)
m
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-arrow a-, and secure it by turning it 90° towards left
om
ion
-arrow b-.
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– Loosen clamping bolt -2- until it is visible in rubber buffer.

a
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Cop py
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Prote AG.
– Check whether dimension -a = 25 mm-, and adjust it as nec‐

essary.
– Close rear lid slowly so that it rests against striker pin.
– Push rear lid down in centre below handle recess using just
enough force to engage rear lid lock in closed position.
– Open rear lid, and tighten set screw -1- to fix adjusting buffer
in position.
Specified torques
Component Specified torque
Adjusting buffer 0.5 Nm
2.4 Removing and installing bonnet lock


satelettronica
AG. Volkswagen AG d
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Removing
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– Remove rear lid trim ⇒ General body repairs, interior; Rep.

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– Unclip operating rod -2- from actuator -1-.

hole
spec
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t to the co
– Pull rear lid lock -3- out of rear lid.

– Disconnect connector -5- from rear lid lock -3-.
rrectness of i
– Remove rear lid lock -3- together with operating rod -2- from
l purpos
rear lid.
Installing
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♦ Operating rod and lid lock must be installed without stress.

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♦ Before installing the rear lid trim and closing the rear lid, check function of the locking and release compo‐
C py
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2. Rear lid 41
Specified torques
2.5 Removing and installing operating

mechanism
Volkswagen AG
⇒ “2.5.1 Removing and installing operating mechanism, with cen‐
agen
AG. does
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⇒ “2.5.2 Removing and installing operating mechanism,
ho
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chanical locking system”, page 44 ss a ra
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⇒ “2.5.3 Removing and installing operating mechanism, child‐
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2.5.1 Removing and installing operating
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AG. Volkswagen AG d
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Removing
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gr. 70 ; Luggage compartment trims; Removing and installing Cop py
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lower rear lid trim . opyri
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– Disconnect connector -5-.
lksw
cted agen
Prote AG.
– Detach reinforcement -3- from hooks on mounting bracket
-2-.
– Lever reinforcement -3- out of rear lid opening.
– Unclip operating rod from actuator.
– Unclip mounting bracket -2- from inside from operating mech‐
anism -1-.
– Release operating mechanism -1- from outside.
Installing
Specified torques
2. Rear lid 43
Transporter 2016 ➤ AG. Volkswagen AG d
General body repairs, exterior - Edition 10.2019 agen oes
olksw not
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2.5.2 Removing and installing operating or eo
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mechanism, with mechanical locking ss c
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AG. Volkswagen AG d
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– Remove rear lid trim ⇒ General body repairs,risinterior; Rep.
ed
nte
gr. 70 ; Luggage compartment trims; Removing
aut
ho
and installing eo
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lower rear lid trim . ss c
ce
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nl
pt
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-2-.
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-2-.
rrectness of i
– Unclip operating rod from actuator.
l purpos
– Unclip mounting bracket -2- from inside from operating mech‐

anism -1-.
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– Release operating mechanism -1- from outside.
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Specified torques
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♦ ⇒ “2.1 Assembly overview - rear lid”, page 34 C py
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2.5.3 Removing and installing operating mechanism, childproof lock
op Vo
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Prote AG.
2. Rear lid 45
satelettronica
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Removing
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– Unclip cover section -2- from operating mechanism -1-. f inform

mer

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– Unclip operating mechanism -1- on inner section of rear lid.

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Installing
C py
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Install in reverse order. cop Vo
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2.6 Removing and installing hinges

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♦ Handbrake adjustment wrench - 3343- ss
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Removing
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Note
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♦ The removal and installation procedure is for the left side. Re‐
t
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♦ Mask off the edge of the roof and the upper edge of the rear
en
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lid to prevent damage to the paintwork. t. Cop py
rig
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♦ Have a second mechanic hold the rear lid in position when pyri by
Vo
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removing the rear lid hinge.
c by lksw
cted agen
Prote AG.
♦ The gas struts remain installed.
– Remove rear roof trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Roof trims; Removing and installing moulded head‐
liner .
– Have a second mechanic hold the rear lid in area of hinge in
position.
2. Rear lid 47
Note
An easy way of loosening nuts -3- is with the handbrake adjust‐

ment tool - 3343- as the guide pins of the hinge -1- are very long.
– Unscrew nuts -3-.

– Pull off hinge -1-.
Installing
Note
Before installing the hinge -1-, check seal -5- for damage, and
renew it as necessary.
– Fit rear lid hinge -1- from outside.
satelettronica
– Start bolts -2-, and tighten them slightly.
– Slide reinforcement plate -3- onto studs on inner roof side
member.
– Start nuts -4-, and tighten them slightly.
– Adjust rear lid -1- ⇒ page 38 .
Specified torques
AG. Volkswagen AG d
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nl
pt
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2.7 Removing and installing striker pin

erm
ab
ility
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⇒ “2.7.1 Removing and installing striker pin”, page 48

wit
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⇒ “2.7.2 Removing and installing striker pin with power latching

hole
spec
motor”, page 49
es, in part or in w
t to the co
2.7.1 Removing and installing striker pin

rrectness of i
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48
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Prote AG.
Rep. gr.55 - Bonnet, rear lid
AG. Volkswagen AG d
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Removing aut ra
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– Remove load sill cover ⇒ General body repairs, interior; Rep.
ce
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nl
pt
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lock carrier trim .
erm
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– Remove striker pin -1- from lock carrier.
h re
hole
satelettronica
spec
Installing
es, in part or in w
t to the co
– Adjust striker pin -1- ⇒ page 38 .
rrectness of i
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2.7.2 Removing and installing striker pin with
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power latching motor

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♦ Torque wrench - V.A.G 1331- Cop py
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Removing
– Remove load sill cover ⇒ General body repairs, interior; Rep.
lock carrier trim .
2. Rear lid 49

– Remove striker pin with power latching motor -1- from lock
carrier.
Installing
2.8 Removing and installing guide

♦ Torque wrench - V.A.G 1783- AG. Volkswagen AG d
agen oes
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Removing
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– Detach guide -1- from rear lid.

Installing
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2.9 Removing and installing rear lid seal
t. rig
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Removing cted agen
Prote AG.
Note
♦ During production, a sealant is applied to the rear lid seals, the

seal is then placed on the door flange and rolled on.
♦ When removing the seal, the sealant is distributed across the
inside of the seal. The edges are bent up slightly. If the seal is
then refitted, sealing and firm seating are no longer guaran‐
teed.
♦ Therefore each seal which is removed completely must be re‐
newed with a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

– If fitted, detach adjacent interior trims ⇒ General body repairs,

interior; Rep. gr. 70 ; Trims, interior; Overview of fitting loca‐
tions- trims, interior .
– Pull rear lid seal -1- off body flange.
Installing
– The vulcanised point -arrow- on the rear lid seal -1- must be
aligned to the middle of the left tail light.
2.10 Removing and installing gas strut
satelettronica
⇒ “2.10.1 Removing and installing gas strut”, page 51
⇒ “2.10.2 Removing and installing motor 1 for rear lid V444 / V445
”, page 53
2.10.1 Removing and installing gas strut
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Cop py
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2. Rear lid 51
satelettronica
AG. Volkswagen AG d
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Removing
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spec
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Note
The removal and installation procedure is for the left side. Removal and installation of the right side is similar.
rrectne
– Open and support rear lid.

ss o
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WARNING
form
mer
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Proceed with care if gas strut is reused. The spring clip must
o
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c
not be levered out completely from the lateral guide slots of the
i
or
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ball socket, as it will otherwise be damaged. The drive unit will

te
sd
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spring out of mounting, causing damage or injury to the oper‐

i
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Cop py
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– Insert a screwdriver -3- (approx. width: 3 mm) into free gap
ht
pyri by
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between spring clip -2- and back of ball socket.
co lksw
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cted agen
Prote AG.
– Swivel screwdriver -3- to lift spring clip -2- out of ball socket
(approx. 3 mm) -arrow a- until ball socket can be easily de‐
tached from ball-head pin -4- by hand.

– Pull gas strut -1- off ball-head pin and mounting bracket -4-
-arrow b-.
After removing gas strut -1-, slide spring clip -2- back immediately.
– When the gas strut is disposed, gas needs to be released from
gas strut ⇒ page 54 .
Removing mounting bracket
– Unclip cap -5-.
– Remove mounting bracket -4-.
Installing
– Press gas strut -1- onto ball-head pins and mounting bracket
-4-.
Specified torques
2.10.2 Removing and installing motor 1 for rear
satelettronica
lid - V444- / -V445-
Removing
– Open and support rear lid.
– Remove tail light cluster ⇒ Electrical system; Rep. gr.
A G. V94
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Tail lights; Removing and installing tail light
Vo lcluster
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– Disconnect connector -1-. pt

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WARNING
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Proceed with care if motors for rear lid are reused. The spring
hole
clip must not be levered out completely from the lateral guide
spec
es, in part or in w
slots of the ball socket, as it will otherwise be damaged. The

t to the co
rear lid motor will spring out of mounting, causing damage or

injury to the operator.
rrectness of i
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– Insert a screwdriver -4- (approx. width: 3 mm) into free gap

between spring clip -2- and back of ball socket.
nf
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– Swivel screwdriver -4- to lift spring clip -2- in direction of

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-of arrow a- out of ball socket (approx. 3 mm) until ball socket
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can be easily detached from ball-head pin -3- by hand.

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2. Rear lid 53
– Insert a screwdriver -3- (approx. width: 3 mm) into free gap agen
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pin on mounting bracket -4-.
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Installing
spec
Install in reverse order of removal, observing the following: es, in part or in w
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Installation instructions:
rrectness of i
♦ Push motor for rear lid onto ball-head pins until it engages.
While doing this, make sure that end of line points downwards,
l purpos
fit drive unit with ball socket onto ball-head pin, and push it on
by hand.
nf
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♦ When routing the lines, make sure that the recess in tail light
orm
can fit into intended section of cable grommet later.
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♦ Securing clips and ball sockets must not show any signs of
or c
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2.11 Releasing gas from gas strut
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WARNING
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Wear protective goggles when sawing.

Cover area of saw cut with a cloth.
Feed oil and cleaning clothes into existing method of disposal.
– Saw open strut cylinder in first third of total cylinder length,

starting from the reference edge on the piston rod side.

3 Tank flap unit

⇒ “3.1 Assembly overview - tank flap unit”, page 55
⇒ “3.2 Removing and installing fuel tank flap”, page 55
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❑ 4.5 Nm
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❑ Qty. 3
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es, in part or in w
4 - Tank flap
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⇒ page 55
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5 - Bolts
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❑ Qty. 3
❑ 4.5 Nm
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6 - Tank flap stop
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3.2 Removing and installing fuel tank flap

3. Tank flap unit 55

satelettronica
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Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - tank flap unit”, page 55
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3. Tank flap unit 57

57 – Front doors, door components, central locking

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⇒ “1.2 Assembly overview - door seals”, page 60 s
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⇒ “1.3 Removing and installing inner door seal”, page 61
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⇒ “1.4 Removing and installing outer door seal”, page 63
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⇒ “1.5 Removing and installing door”, page 64
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⇒ “1.6 Greasing new door hinges”, page 66
spec
es, in part or in w
⇒ “1.7 Adjusting door”, page 66
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⇒ “1.8 Adjusting striker pin”, page 69
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1.1 Assembly overview - door
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Note
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♦ The illustrations show the left-hand side. The right side is analogous.
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♦ The hinge bolts must always be renewed if loosened.
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58 Rep. gr.57 - Front doors, door components, central locking

1 - Door
⇒ page 64
2 - Bolts
❑ Upper and lower
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ 27 Nm
3 - Door upper hinge
❑ Hinge is split.
4 - Bolt
❑ Installed from inside ve‐
hicle
❑ Allocation ⇒ Electronic n AG. Volkswagen AG do
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❑ To loosen or tighten ris tee
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bolt: aut or
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❑ Remove left dash panel
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trim ⇒ General body re‐
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pairs, interior; Rep. gr.
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70 ; Dash panel; Re‐
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dash panel end cover
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❑ Remove dash panel in‐
spec
sert ⇒ Electrical sys‐
t to the co
tem; Rep. gr. 90 ; Dash
panel insert; Removing
and installing dash pan‐
el insert -KX2-
rrectne
❑ 20 Nm +90°
5 - Bolts ss o
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❑ Allocation ⇒ Electronic parts catalogue (ETKA)

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❑ Installed from inside vehicle
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❑ To loosen or tighten multi-point socket head bolt:
❑ Remove left dash panel trim ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel end cover
❑ Remove bonnet lock release lever ⇒ page 22 .
❑ 20 Nm +90°
8 - Bolts
❑ Qty. 3
1. Door 59
❑ 20 Nm +90°
1.2 Assembly overview - door seals

⇒ “1.2.1 Assembly overview - door seals”, page 60
⇒ “1.2.2 Assembly overview - additional seals for postal and cou‐
rier vehicles”, page 61
1.2.1 Assembly overview - door seals

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1.2.2 Assembly overview - additional seals for postal and courier vehicles au ra
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1 - Buffer stop
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❑ Bond stop buffer to bot‐
ility
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passenger door
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spec
2 - Rear door
t to the co
⇒ page 64
3 - Protective sheet
rrectne
❑ Door seal protective foil,
attached so that it ex‐
ss o
tends approx. 3 mm into
cial p
f i
area of radius
nform
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4 - Protective foil
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❑ Attaching protective foil
n
c
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in area of B-pillar
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1.3 Removing and installing inner door seal

⇒ “1.3.1 Removing and installing inner door seal”, page 61
⇒ “1.3.2 Removing and installing door seal”, page 62
1.3.1 Removing and installing inner door seal

During production, a sealant is applied to the inner door seals,
which are then placed on the door flange and rolled on.
1. Door 61
Note
♦ Removal and installation are described only for the right side.
The removal and installation procedure for the left-hand side
is basically the same.
teed.
♦ Therefore each seal which is removed completely
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Rep. gr. 70 ; Trims, interior; Overview of fitting locations -
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– Pull inner door seal -1- off body flange.
hole
spec
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Installing
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– The inner door seal -1- must be fitted with the vulcanised point
rrectness of i
-arrow- located on the body flange above the rear radius.
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– Press inner door seal -1- onto body flange.
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Note
Removal and installation are described only for the right side. The
removal and installation procedure for the left-hand side is basi‐
cally the same.

satelettronica
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Removing
spec
es, in part or in w
– Pull short door seal -1- or long door seal -3- (depending on
t to the co
model) off roof side member -2-.

Installing
rrectness of i

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– Clean roof side member in assembly area with adhesive re‐

mover.
nform
ercia
• Bonding surfaces must be free of dirt, dust, grease and other

m
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contaminants and must be dry.

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• Remove protective backing immediately before installation of

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door seal.
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1.4 Removing and installing outer door seal

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Removal and installation are described only for the left side. Re‐
1. Door 63
Removing
– Unclip outer door seal -1- from edge of door.
– Unclip outer door seal -2- from edge of door.
Installing
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Before installing outer door seals, check fastening elements -3-,c
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and renew them as necessary.
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1.5 Removing and installing door
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♦ Torque wrench - V.A.G 1331- nform
mercia
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Note
♦ Removal and installation are described only for the left side. Removal and installation of the right side is
similar.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.

AG. Volkswagen AG d
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aut General body repairs, exterior - Edition 10.2019 ra
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Removing
– Remove wing triangular cover ⇒ page 330 .
– Remove left dash panel trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Dash panel; Removing and installing dash panel
end cover .
– Release bellows -1- by pressing catch -2- on the side.
– Pull bellows off A-pillar.
– Disconnect electrical connectors -arrows-.
– Fold floor covering in left footwell towards side.
– Disconnect earth wire from star connection.
– Guide lines through the hole.
– Remove protective caps -3- and -5- (if there are any).
– Unscrew bolt -4-.
– Lift door upwards out of hinges.
Installing
1. Door 65
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General body
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• Then check function with door open.
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Specified torques
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♦ ⇒ “1.1 Assembly overview - door”, page 58
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1.6 Greasing new door hinges
h re
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spec
t to the co
Note
♦ The new door hinge is greased after painting.
rrectne
♦ Lithium grease; allocation ⇒ Electronic parts catalogue (ET‐
s
KA)
s o
cial p
f inform
– Grease pin and hole of upper door hinge all round using lithium
mer
grease.
atio
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n
c
– Grease pin and hole of lower hinge all round using lithium
i
or
n thi
grease.
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– Grease torsion spring of door arrester on lower hinge with lith‐

p
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1.7 Adjusting door
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AG.
equipment required

♦ Key (for door alignment) - 3320-

♦ Universal joint for 3320 - 3320/1-
♦ Bit for 3320 - 3320/2-
♦ Bit for 3320 - 3320/3-
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♦ Setting gauge - 3371-rised b ara
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♦ Removal wedge s- a3409-
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is similar (components are not identical).
h re
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spec
Adjusting door hinges
es, in part or in w
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satelettronica
Note
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♦ Vehicle must be standing on its wheels to enable front door to
l purpos
be adjusted.
♦ To ensure correct door adjustment, the door hinge on the A-
nform
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pillar must be loosened. Other measures, such as raising the

m
door, will prove pointless. Pressure from above will cause the
at
om
io
door to drop again.
n
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♦ The front door is adjusted correctly if the gaps/shut lines are
ate
do
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even all around, the door is not too deep or does not stand
p
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proud and all contours align when the is door closed.

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♦ Checking gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Panel Cop py
gaps/shut lines; Body - front
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♦ If there is a requirement to loosen the door hinge on the A-
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pillar from the interior, an M8 multi-point socket from the tool
Prote AG.
set - V.A.G 1816/2- can be used.

♦ The hinge bolts must always be renewed if loosened.
♦ After completing installation or adjustment, corrosion protec‐
tion measures must be carried out on hinge and bolts.
1. Door 67
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Correct adjustment to achieve a flush fitting is carried out via the

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bolts on the door hinge.

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Use special door alignment tool - 3320- with bit - 3320/3- .

thi
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Top door hinges:

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– To adjust upper section of door -1- at hinges -5-, loosen bolts

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-4- and -6-. C py
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– To access bolt -4-, remove dash panel insert ⇒ Electrical sys‐ cop Vo
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Prote AG.
dash panel insert -KX2- .
– ⇒ General body repairs, interior; Rep. gr. 70 ; Central tube
for dash panel; Removing and installing central tube for dash
panel
Bottom door hinges:
– To adjust door -1- in lower area at hinges -7- loosen bolts -6-
and -8-.
– To access bolt -8-, remove dash panel trim on left ⇒ General
body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel end cover .
– Remove bonnet lock release lever ⇒ page 22 .

Specified torque
♦ ⇒ “1.1 Assembly overview - door”, page 58
1.8 Adjusting striker pin

AG. Volkswagen AG d
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Note
♦ Adjustment is described only for the left door. Adjustment of
rrectness of i
the right door is analogous.
l purpos
♦ The door must lock fully when closing without any additional
force being required, and there must be no play.
nf
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♦ Do not permit the striker plate adjustment to push the door up
rm
m
or down.
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♦ Striker pin is correctly adjusted when lid lock recess engages

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with rotary latch central to striker pin.

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Striker pin can be used to align front door flush with side panel (to
f
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reduce wind noise) -arrows-.
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– Loosen striker pin -1- by loosening bolts -2- in B-pillar.
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Prote AG.
Note
Greater forced has to be applied so that position of striker pin

-1- can be adjusted when bolts -2- are loosened.
– Adjust door by means of striker pin -1- so that the door is flush
with the side panel when shut (to prevent wind noise).
– Tighten bolts -2- of striker pin -1-.
Specified torques
Striker 20 Nm
1. Door 69
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⇒ “2.1 Assembly overview - subframe”, page 70 horis nte
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⇒ “2.2 Assembly overview - window regulator”, page 72 ss c
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⇒ “2.3 Assembly overview - door handle and door lock”,
an
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page 73
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⇒ “2.4 Assembly overview - window channels and window slot
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(aperture) seals”, page 74
is n
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⇒ “2.5 Removing and installing window regulator motor”,
spec
page 75
t to the co
⇒ “2.6 Removing and installing window crank”, page 75
⇒ “2.7 Removing and installing subframe”, page 76
rrectne
⇒ “2.8 Removing and installing lock cylinder”, page 78
s
⇒ “2.9 Removing and installing door handle”, page 80
s o
cial p
f in
⇒ “2.10 Removing and installing door lock”, page 82
form
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⇒ “2.11 Removing and installing mounting bracket”, page 85
atio
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2.1 Assembly overview - subframe

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1 - Bolts
❑ Qty. 2
❑ 20 Nm
2 - Clip with locking rod
3 - Bellows
4 - Locking rod
5 - Plug
❑ For assembly holes.
❑ Qty. 2
6 - Earth connection bolt
❑ Beneath window slot in‐
ner seal
7 - Bolts
❑ Qty. 8
❑ 10 Nm
8 - Window regulator motor
satelettronica
⇒ page 75
9 - Rubber grommet
10 - Loudspeakers
❑ ⇒ Communication;
Rep. gr. 91 ; Sound sys‐
tem; Overview of fitting
locations - sound sys‐ AG. Volkswagen AG d
tem agen oes
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11 - Bolts rise
d
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❑ Qty. 2 s aut ra
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s
❑ 10 Nm
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12 - Wiring harness
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13 - Rubber grommet ility
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2. Door components 71
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ed ran
Transporter 2016 ➤ hor is tee
t or
General body repairs,
au exterior - Edition 10.2019 ac
ss
ce
e
nl
pt
2.2 Assembly overview - window regulator
du
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itte
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ility
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Note
wit
, is n
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hole
spec
es, in part or in w
t to the co
1 - Subframe
rrectness of i
❑ Part for window regula‐
tor
l purpos

⇒ page 76
nform
ercia
2 - Spacer
m
at
om
❑ For window crank
ion
c
in t
or
3 - Window crank
his
ate
do
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4 - Window regulator
p
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for
en
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❑ For manual operation

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op
satelettronica
C py
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⇒ page 76
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5 - Window regulator
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Prote AG.
❑ Without motor
⇒ page 76
6 - Window regulator motor
⇒ page 75
7 - Bolts
❑ Qty. 3
❑ 3.5 Nm
8 - Bolts
❑ Qty. 8
❑ 9 Nm

2.3 Assembly overview - door handle and door lock
Note
♦ The illustrations show the left-hand side. The right side is analogous.
♦ Minor differences may be encountered during repair work, depending on vehicle model.
1 - Door lock
❑ The door lock can be re‐
moved only together
with the assembly carri‐
er.
⇒ page 82
2 - Bolts
❑ Qty. 2
❑ 20 Nm
satelettronica
3 - Bolt
❑ 2 Nm
4 - Retaining plate
5 - Carrier
6 - Lock cylinder
❑ Lock cylinder is not sup‐
plied as individual parts.
❑ Lock cylinder only on
driver side, otherwise swa
gen AG
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❑ Removing and installingorise nte
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⇒ page 78 au
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7 - Cover
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❑ For lock cylinder

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❑ Secured to lock cylinder

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with 3 locking lugs

wit
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8 - Key
hole
spec
❑ Changing battery on re‐

es, in part or in w
mote control
t to the co
⇒ page 92
❑ Changing battery on key
with light ⇒ page 92
rrectness of i
9 - Door handle
l purpos

nform
ercia
10 - Bolt
m
❑ 4.5 Nm
at
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ion
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or
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12 - Cover
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❑ Not supplied with door lock.
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13 - Bowden cable
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❑ For releasing door interior handle lock Prote
cted AG.
agen
14 - Retaining bracket
❑ Bolted and riveted to door lock.
❑ Not supplied with door lock.
15 - Bowden cable
❑ For releasing outside door handle lock
2.4 Assembly overview - window channels

and window slot (aperture) seals AG. Volkswagen AG d
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Note orise nte
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♦ The core of the window slot outer seal is a metal insert. s
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un
pt
♦ If it is bent or distorted, the window slot outer seal can no lon‐
an
d
itte
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ger be straightened out.
rm
ab
pe
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♦ When removing or installing the window slot outer seal, make
ot
wit
, is n
sure to pull it off or push it on uniformly and without bending
h re
it.
hole
satelettronica
spec
es, in part or in w
t to the co
1 - Rear door
2 - Window slot inner seal
rrectness of i
❑ Pushed onto door
l purpos
flange
3 - Window slot outer seal
nform
mercia
a
Note
com
tion in
r
te o
The outer window slot seal is
thi
s
iva
straight when delivered and must be
do
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manually bent to fit the contour.
cum
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❑ Pushed onto door
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4 - Window channel
c by lksw
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Prote AG.
❑ Pushed onto door frame

2.5 Removing and installing window regula‐

tor motor
AG. Volkswagen AG d
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Removing
nl
pt
du
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itte
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ab
satelettronica
Note
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove front door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Front door trim; Removing and installing front door
trim .
– Secure door window using adhesive tape. rrectness of i
l purpos
– Disconnect electrical connectors -3-.

nf
ercia

orm
m
atio
– Remove window regulator motor with control unit -1- from as‐
om
n in
sembly carrier.
or c
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Installing
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– Operate window regulator once in each direction to upper and t. Cop py
lower stops. This initialises the window regulator motor and it
rig
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is now ready for operation. op Vo
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Check function of window regulator after installation.
AG.
Specified torques
♦ ⇒ “2.2 Assembly overview - window regulator”, page 72
2.6 Removing and installing window crank

Removing
Note
Removal and installation are described only for the left side. The
removal and installation procedure for the right-hand side is ba‐
sically the same.
– Push spacer ring -4- in direction of -arrow- (securing clip will

be released).
– Pull window crank -3- off drive unit -1-.
– Remove spacer -2- from drive unit -1-.
AG. Volkswagen AG d
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Install in reverse orderorofis removal, observing the following:
e nte
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– After fitting window
ss a crank -3-, engage spacer ring -4- in zero c
position.
ce
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2.7 Removing and installing subframe
wit
is n
h re
ole,
spec
t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
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or
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te
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Cop py
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Removal and installation are described only for the left side. Re‐ Prote AG.
Window regulator, door lock and loudspeaker are secured to the

assembly carrier.
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.
If door window cannot be lowered with electric window regulators,
first determine the precise cause of the fault.
If an electrical fault exists, rectify it first.
If the electrical fault is due to the window regulator motor, it can
be unbolted from the assembly carrier. The door window can be
pushed into the necessary working positions by hand.
trim .
– Remove lock cylinder ⇒ page 78 .

AG. Volkswagen AG d
agen oes Transporter 2016 ➤
olksw not
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ed b General ara body repairs,
nte
exterior - Edition 10.2019
ris
ho eo
ut ra
– Loosen clipss-1- from door handle -2- ⇒ page 80 .
a c
ce
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nl
pt
du
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itte
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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atio
om
n in
or c
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Cop py
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– Lever out sealing plugs -5-.
– Unscrew earth cable connection -6- from beneath window slot

seal.
– Lower door window until clamping bolts -11- for door window
become accessible.
Note
If work is not possible due to a malfunction caused by electric window regulator, the window regulator motor
can be unbolted. The door window can then be pushed into the necessary working position by hand.
– Loosen clamping bolts for door window -11- (do not unscrew
completely).
– Press apart clamping jaws.
– Slide door window upwards, and secure it (e.g. with adhesive
tape). agen
AG. Volkswagen AG d
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– Lever out boot -3-. Vol gu
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– Disconnect electrical connectors -8- and -10-. utho eo
ra
a c
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satelettronica
ce
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nl
pt
du
an
– Remove bolts -7- (qty. 8).
itte
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erm
ab
– Pull subframe at top off door, lift it slightly, and swing it out of
ility
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door towards hinge side together with door lock and locking
wit
, is n
rod -4-.
h re
hole
spec
– Turn over assembly carrier, and disconnect connector from
es, in part or in w
door lock.
t to the co
– Pull off clips of electrical wiring on back of subframe.
– Lever out rubber grommet -13-.
rrectness of i
– Pull line -12- out of opening -13- and out of rubber grommet
l purpos
-9-.
Installing
nf
ercia
orm
m
atio
om
n in
c
– Insert assembly carrier in door.

or
thi
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sd
– Start bolts -arrows-.

iva
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• Observe bolting sequence on subframe.

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– Tighten bolt -1- first, then tighten bolt -2- to specified torque. Cop py
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– Then, tighten remaining bolts -arrows- in diagonal sequence p by
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by
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• Then check function with door open.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 70
2.8 Removing and installing lock cylinder


♦ Socket wrench - T10072-
AG. Volkswagen AG d
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Removing s aut ra
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s
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pt
du
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Note
itte
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ab
ility
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Removal and installation are described only for the left side. The
wit
removal and installation of the right side are similar.
, is n
h re
hole
satelettronica
spec
– Lever cap -1- out of opening.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
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– Pull door handle -1- in -direction of arrow-.

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– Loosen bolt -2- (do not unscrew completely) while pushing Cop py
onto socket wrench TORX T20 - T 10072- .
t. rig
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co
When loosening bolt -2-, the catch for lock cylinder -3- is released.
by lksw
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Prote AG.
– Pull lock cylinder -3- at right angles out of mounting bracket.
Installing
– Note mounting bracket installation instructions ⇒ page 85 .
– Insert lock cylinder -3- at right angles into mounting bracket of

door -1-.
The door handle must rest only lightly against outer door panel.
– Screw bolt -2- into mounting bracket using socket wrench
TORX T20 - T 10072- .
The door handle engages in the lock cylinder with an audible click.
Note agen
AG. Volkswagen AG d
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During installation, the lock cylinder must be pressed againstorthe
d
ise nte
outer door panel. The door handle just rests lightly againstauthe
th eo
ra
outer panel of door. ss c
ce
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un
pt
an
d
Then, always check function with door open.
itte
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erm
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ility
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2.9 Removing and installing door handle
wit
is n
h re
ole,
spec
♦ Assembly tool - T10118-
satelettronica
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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♦ The removal and installation sequence is only for the left door cted agen
Prote AG.
handle. The removal and installation of the right door handle
is similar.
♦ The removal and installation procedures may have to be modi‐
fied slightly depending on variations in equipment.

Removing
– Release clip -1- from door handle -2-.
– Swing door handle -2- out of door.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
ss c ce
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un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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fo
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t.
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Cop py
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Prote AG.
Installing
– Guide assembly tool - T 10118- through the opening on the
inside of the door panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool in spring -arrow A-.
– When pulling assembly tool -arrow B-, the spring is attached
in the door lock.
The release lever is now secured.
Note
Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden
cable to the door handle later.
– Swing door handle -2- into door.
satelettronica
– Engage clip -1- in door handle -2-.
AG. Volkswagen AG d
agen oes
lksw not
Note d by
Vo gu
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♦ Press door handle -2- against outer panel of door when
s autas‐ ra
c
sembling. s
ce
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nl
pt
du
♦ Clip -1- must engage audibly in door handle -2-.
an
itte
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erm
ab
ility
– Install lock cylinder ⇒ page 78 .
ot p
wit
, is n
It is essential that the function then be checked with the door
h re
hole
open.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.10 Removing and installing door lock

nf
ercia
orm
m
atio
Note
om
n in
or c
thi
♦ Removal and installation are described only for the left door
te
sd
a
lock. The removal and installation of the right door lock is sim‐
iv
o
r
rp
cu
ilar.
o
m
f
en
ng
t.
yi
Co
op py
fied slightly depending on variations in equipment. t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

satelettronica
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Removing utho
or
a ac
ss
– Remove subframe ⇒ page 76 .
ce
le
un
pt
– Drill out pop rivets -5- of subframe -4-.

an
d
itte
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rm
ab
– Turn cable nipple -6- 90° and remove Bowden cable from eye‐
pe
ility
let.
ot
wit
, is n
h re
– Release locking tabs of cap -8- from door lock -1-.

hole
spec
– Remove securing rod -2-.

es, in part or in w
t to the co
– Drill out pop rivet -7-.

– Remove retaining bracket -3- from door lock -1-.
rrectness of i
l purpos
Note
nform
ercia
The retaining bracket is not part of the items supplied with the door lock. Always renew retaining bracket if it is
removed.
m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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83
co Vo
by lksw
cted 2. Door components
agen
Prote AG.
lkswage es n
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satelettronica
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Installing
m
at
om

ion
c
in t
or
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ate
do
riv
Note
p
cum
for
en
ng
Open holes must be sealed with film ⇒ Electronic parts catalogue (ETKA) .
t.
yi Co
Cop py
t. rig
gh ht
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– Pull release lever -1- in -direction of arrow-.
p by
co Vo
by lksw
cted agen
– Using a screwdriver, tension retaining spring -2-, which is se‐
Prote AG.
cured on door lock, in -direction of arrow-, and hook locking

lever into spring.
Note
Hooking the operating lever in locks the lock. This prevents “incorrect” attachment of the Bowden cable later.
Then check function with door open.

2.11 Removing and installing mounting

bracket
AG. Volkswagen AG d
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Removing by Vol not
gu
d ara
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– Remove subframe ⇒ page 76 . thor eo
satelettronica
au ra
c
– Unscrew bolt -2-. ss
ce
e
nl
pt
du
– Push mounting bracket -3- slightly towards rear, and remove
an
itte
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it from door -1-.
erm
ab
ility
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Installing
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
When the lock cylinder or door handle is removed, the relay lever
l purpos
-3- may separate from the locking bar -2-.

– Pull relay lever -3- towards mounting bracket -1-.
nf
ercia
orm
– Push locking bar -2- in direction of relay lever -3-.
m
atio
om
– Tips of relay lever -3- must be located in notches of locking
n in
or c
bar -2- -arrows-.

thi
te
sd
iva
When installing the components, make sure that the position is

o
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o
not changed.
m
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en
ng
t.
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Specified torques Cop py
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Component Specified torque cop Vo
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Prote
Mounting bracket 4.5 Nm
AG.
2.12 Removing and installing striker pin

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
Transporter 2016 ➤ oris nte
eo
th
General body repairs, exterior - Edition
s au10.2019 ra
c
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
Note
com
tion in
r
te o
thi
s
iva
do
r
rp
c
cally the same.
um
fo
en
ng
t.
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op
satelettronica
Removing
C py
ht. rig
rig ht
py by
– Unscrew bolts -2-. co Vo
by lksw
cted agen
Prote AG.
– Remove striker pin -1-.
Installing

3 Central locking
⇒ “3.1 Overview of fitting locations - central locking”, page 87
⇒ “3.2 Assembly overview - ignition key”, page 90
⇒ “3.3 Removing and installing ignition key battery”, page 92
3.1 Overview of fitting locations - central locking
1 - Coupling station
❑ Location: under dash
panel on front passen‐
ger side
❑ Remove trim under
dash panel to discon‐
nect connector ⇒ Gen‐
eral body repairs, interi‐
or; Rep. gr. 70 ; Dash
panel; Removing and in‐
stalling dash panel end
cover .
satelettronica
AG. Volkswagen AG d
agen
2 - Convenience system cen‐ Volksw
oes
not
gu
tral control unit - J393- ed by ara
nte
ris
❑ Location: On seat box ut
ho eo
ra
(on left under front pas‐ ss a c
senger seat).
ce
le
un
pt
an
d
3 - Sliding door button - E442-

itte
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❑ Location: Middle of dash
ility
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panel.
wit
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❑ ⇒ Electrical system;
ole,
Rep. gr. 96 ; Controls;
spec
Removing and installing
t to the co
switches in centre of
dash panel on right,
Multivan
rrectne
4 - Front passenger door con‐
trol unit - J387-
ss
❑ Location: integrated in
o
cial p
f i
window regulator motor
nform
mer

window regulator motor atio
om
⇒ page 75
c
i
or
n thi
te
sd
5 - Door lock on front passen‐

iva
o
r
ger side
p
cum
r
fo
en
ng
❑ Fitting location: door lock is secured to subframe

t.
yi Co
op
❑ Electric central locking is integrated into door lock.
C py
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6 - Remote release mechanism
Prote AG.
❑ Right
❑ Fitting location: sender unit is secured in sliding door
7 - Right electric sliding door sender unit - G481-
❑ Fitting location: sender unit is secured in sliding door
8 - Sliding door power latching motor - V324-
❑ Right
3. Central locking 87
❑ Fitting location: power latching motor is secured in C-pillar
9 - Right sliding door control unit - J731-
❑ Location: sliding door control unit is secured in D-pillar side panel.
10 - Coupling station, rear lid
❑ Right
❑ Location: right D-pillar
❑ Remove right D-pillar trim ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, interior; Removing and
installing D-pillar trim .
11 - Rear lid lock motor (for power latching system)
AG. Volkswagen AG d
❑ Fitting location: lock unit is secured agen
kswon rear load sill
oes
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❑ Adjusting ⇒ page 38 sed b ara
n ri tee
ho
12 - Rear lid actuator au
t or
ac
ss
❑ Location: Bolted to rear lid.
ce
le
un
pt
an
d
itte
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ab
13 - Coupling station, rear lid
satelettronica
ility
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❑ Left
wit
is n
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❑ Location: left D-pillar
ole,
spec
❑ Remove left D-pillar trim ⇒ General body repairs, interior; Rep. gr. 70 ; Trims, interior; Removing and
installing D-pillar trim .
t to the co
14 - Left sliding door control unit - J558-
❑ Fitting location: sliding door control unit is secured in D-pillar side panel
rrectne
15 - Sliding door power latching motor - V324- ss o
cial p
f i
❑ Left
nform
mer
❑ Fitting location: power latching motor is secured in C-pillar

atio
m

o
n
c
i
or
n thi
e
16 - Rear lid lock

t
sd
iva
o
r
❑ Location: bolted to rear lid

p
cum
r
fo
en
ng
❑ Removing and installing ⇒ page 40 yi

t.
Co
op py
17 - Sliding door sender unit - G477-
. C rig
ht ht
rig by
py
❑ Fitting location: sender unit is secured in sliding door co Vo
by lksw
cted agen
❑ Removing and installing ⇒ page 148 Prote AG.

❑ Left
❑ Fitting location: remote release is secured in sliding door
❑ Electric central locking is integrated in the remote release.
19 - Door lock on driver side
❑ Fitting location: door lock is secured to subframe
❑ Electric central locking is integrated into door lock.
20 - Central switch for window regulators
❑ Fitting location: in door trim
❑ Removing and installing ⇒ Electrical system; Rep. gr. 96 ; Controls; Removing and installing operating
unit for window regulator in driver door .

21 - Driver door control unit - J386-

❑ Location: integrated in window regulator motor
22 - Coupling station AG. Volkswagen AG d
agen oes
ksw
❑ Location: Under dash panel by V on driver side.
ol not
gu
ara
ed
❑ Remove trim underhodash panel to disconnect connector ⇒ General
ris nte
e o body repairs, interior; Rep. gr. 70 ;
Dash panel; Removing
au
t and installing dash panel end cover . ra
c
ss
23 - Alarm horn - H12-
ce
le
un
pt
an
d
❑ Fitting location: in plenum chamber

itte
y li
erm
ab
24 - Bonnet lock
ility
ot p
wit
❑ With bonnet contact switch - F266-
is n
h re
ole,
❑ Location: On lock carrier.
spec
t to the co
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.2 Assembly overview - ignition key

⇒ “3.2.1 Assembly overview - ignition key with light”, page 90
⇒ “3.2.2 Assembly overview - ignition key, central locking sys‐
tem”, page 91
3.2.1 Assembly overview - ignition key with light
1 - Bulb
2 - Battery
⇒ page 92
3 - Operating handle
4 - Key cover
5 - Key with light
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
90
by lksw
cted agen
Rep. gr.57 - Front doors, door components, central locking Prote AG.
3.2.2 Assembly overview - ignition key, central locking system
1 - Key with transmitter unit

❑ Transmitter unit can be agen
AG. Volkswagen AG d
oes
renewed individually olksw not
byV gu
ara
ed
nte
2 - LED horis
eo
ut ra
❑ When remote control is ss a c
operated, this LED must
ce
le
un
pt
flash briefly
an
d
itte
y li
❑ If LED does not flash
erm
ab
during remote control
ility
ot p
operation, the battery is
wit
is n
dead and must be re‐
h re
ole,
newed.
spec
3 - Battery
t to the co
battery ⇒ page 94
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.3 Removing and installing ignition key bat‐

tery
⇒ “3.3.1 Removing and installing battery for illuminated key”, page
92
⇒ “3.3.2 Removing and installing battery for ignition key with cen‐
tral locking”, page 94
3.3.1 Removing and installing battery for illu‐

minated key
Removing
– Insert a screwdriver -2- in slot -3- between key -4- and cover
-1-.
– Turn screwdriver -2- in -direction of arrow-.
– Push cover -1- off key -4-.
AG. Volkswagen AG d
agen oes
olksw not
satelettronica
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen
Volksw
oes
not Transporter 2016 ➤
by gu
ed General body repairs, exterior
ara
nte - Edition 10.2019
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
satelettronica
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Detach cover -4-.

– Remove battery -2- from control button -3-.
Installing
Note
Ensure correct polarity and mounting position when installing bat‐

tery.
– Insert battery -2- with positive terminal facing downwards in

control button -3-.
– Fit cover -4- to control button -3-.
– The cover -4- and key -5- are engaged by applying slight pres‐
sure.
3.3.2 Removing and installing battery for igni‐

tion key with central locking
Removing
– Folding out key bit -1- -arrow a-.
– Use a small screwdriver -3- to raise the cover of battery com‐
partment -2- -arrow b-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Use a small screwdriver -3- to lift battery -1- outorof
is battery
e nte
eo
compartment -2- -arrow-. aut
h
ra
ss c
Installing
ce
le
satelettronica
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
♦ Before installing battery, always press any key once.
t to the co
♦ This resets the transmitter unit so that it can detect a new bat‐
tery.
rrectne
Ensure correct polarity and mounting position when installing bat‐
tery. The positive pole is marked.
ss o
cial p
f i
– Insert battery -1- into battery compartment -2- by pressing
nform
slightly -arrow a-.
mer
atio
m
– Assemble cover of battery compartment -3- and transmitter

o
n
c
unit -arrow b-.

i
or
n thi
te
sd
a
Keys with remote control are adapted using ⇒ Vehicle diagnostic

iv
o
pr
tester.
um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

58 – Rear doors, door components

AG. Volkswagen AG d
agen oes
ksw
1 Sliding door ol not
y V gu
d b ara
rise nte
o eo
⇒ “1.1 Assembly overview – sliding door”, page 95auth
ra
ss c
⇒ “1.2 Removing and installing inner door seal”, page 102
ce
e
nl
pt
du
an
⇒ “1.4 Removing and installing sliding door”, page 104
itte
y li
erm
ab
⇒ “1.5 Adjusting sliding door”, page 105
ility
ot p
wit
, is n
h re
hole
spec
⇒ “1.7 Removing and installing lower roller guide”, page 114
es, in part or in w
t to the co
⇒ “1.8 Removing and installing door arrester”, page 115
⇒ “1.9 Removing and installing hinge”, page 115
rrectness of i
⇒ “1.10 Removing and installing door lock”, page 116
l purpos
⇒ “1.11 Removing and installing sliding door remote release

mechanism”, page 117
satelettronica
nf
ercia
⇒ “1.12 Removing and installing contact module and contact
orm
strip”, page 119
m
atio
om
n in
⇒ “1.13 Removing and installing lock cylinder and outer door han‐
or c
thi
dle”, page 121
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
⇒ “1.15 Removing and installing interior door handle”,

t.
yi Co
op
page 122
C py
t. rig
gh ht
yri by
⇒ “1.16 Removing and installing upper guide rail”, page 124 cop Vo
by lksw
cted agen
Prote
⇒ “1.17 Removing and installing middle guide rail”, page 126
AG.
1.1 Assembly overview – sliding door

⇒ “1.1.1 Assembly overview - sliding door roller guides”,
page 95
⇒ “1.1.2 Assembly overview - sliding door locking and release
components”, page 97
⇒ “1.1.3 Assembly overview - sliding door remote release mech‐
anism”, page 99
⇒ “1.1.4 Assembly overview - interior operating mechanism”,
page 100
⇒ “1.1.5 Assembly overview - middle guide rail”, page 101
⇒ “1.1.6 Assembly overview - middle guide rail, long wheelbase”,
page 102
1.1.1 Assembly overview - sliding door roller guides
Note
Only the right side is shown. The left side is similar.
1. Sliding door 95
1 - Sliding door
⇒ page 104 AG. Volkswagen AG d
agen oes
❑ Adjusting ⇒ page 105 olksw not
byV gu
ara
ed
nte
2 - Bolts horis
eo
ut ra
❑ Qty. 2 ss a c
ce
e
❑ 20 Nm
nl
pt
du
an
itte
y li
3 - Upper roller guide
erm
ab
ility
ot p
wit
, is n
4 - Upper locking peg
h re
hole
spec
es, in part or in w
t to the co
5 - Bolts
❑ Qty. 2
❑ 20 Nm
rrectness of i
6 - Lower locking peg
l purpos
satelettronica
nform
ercia
7 - Bolts
❑ Qty. 2
m
at
om
io
❑ 20 Nm
n
c
in t
or
his
e
8 - Lower roller guide

at
do
priv
c
❑ With arrester
um
for
en
g
❑ Lower roller guide with

n
t.
yi Co
op
no arrester in vehicles C py
ht. rig
with electric sliding door rig ht
py by
o Vo
by c lksw
cted agen
⇒ page 114
Prote AG.

9 - Bolts
❑ Qty. 3
❑ 20 Nm
10 - Bolts
❑ Qty. 2
❑ 65 Nm
11 - Hinge seal
12 - Hinge
13 - Bolts
❑ Qty. 2 for door lock
❑ 18 Nm
96 Rep. gr.58 - Rear doors, door components

AG. Volkswagen AG d
agen oes
olksw not
1.1.2 Assembly overview - sliding door locking and release components
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1 - Sliding door
hole
spec
es, in part or in w
⇒ page 104
t to the co
2 - Rubber buffer
rrectness of i
❑ Qty. 2
l purpos
nf
ercia
3 - Door lock
orm
m
atio
m
⇒ page 116
o
n in
or c
satelettronica
4 - Door joint seal
thi
te
sd
iva
o
r
rp
cu
⇒ page 102
o
m
f
en
ng
t.
yi Co
5 - Stop t. Cop py
rig
gh ht
yri
6 - Bolt p by
co Vo
by lksw
❑ 20 Nm
cted agen
Prote AG.
7 - Contact module (sliding

door)
⇒ page 119
8 - Bolts
❑ Qty. 2
❑ 3 Nm
9 - Childproof lock
❑ Removing ⇒ page 117
10 - Lower locking peg
11 - Bolts
❑ Qty. 2
❑ 20 Nm
12 - Bolts
❑ Qty. 2
❑ 20 Nm
13 - Catch plate for lower locking pegs
❑ Catch plate for locking pegs bolted into B-pillar.
14 - Exterior door handle
15 - Lock cylinder
1. Sliding door 97
16 - Carrier
17 - Bolts
❑ 4.5 Nm
18 - Bolts
❑ Qty. 2
❑ 20 Nm
19 - Catch plate for upper locking pegs
❑ Catch plate for locking pegs bolted into B-pillar.
20 - Bolts
❑ Qty. 2
❑ 20 Nm
21 - Upper locking peg
22 - Interior operating mechanism
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
98
cop Vo
by lksw
Rep. gr.58 - Rear doors, door components Prote
cted AG.
agen
1.1.3 Assembly overview - sliding door remote release mechanism
Note
♦ Only the right side is shown. The left side is similar.

♦ Vehicles without central locking system are also similar.
1 - Remote release mecha‐

nism
⇒ page 117
2 - Electrical connector
3 - Bowden cable
❑ To door lock
4 - Bowden cable
❑ To lower roller guide
satelettronica
with door arrester.
5 - Water collector
❑ Mounted on door handle
AG. Volkswagen AG d
mounting bracket. lksw
agen oes
not
Vo
❑ Can only be removed in d by gu
ara
connection with remote rise nte
tho eo
actuation s au ra
c
s
ce
6 - Clip
e
nl
pt
du
an
❑ Qty. 2
itte
y li
erm
ab
7 - Water drain plugs
ility
ot p
wit
, is n
8 - Water drain hose

h re
hole
9 - Bolts spec
es, in part or in w
❑ Qty. 3
t to the co
❑ 9 Nm
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Sliding door 99
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Transporter 2016 ➤ rised
nte
o eo
aut
h
- Edition 10.2019 ra
ss c
ce
le
1.1.4 Assembly overview - interior operating mechanism
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
t to the co
1 - Locking element
rrectne
2 - Interior opening mechanism
trim
ss
3 - Interior operating mecha‐
o
cial p
f
nism
inform
mer
atio
⇒ page 122
om
n
c
i
or
n
4 - Operating rod to relay lever
thi
te
sd
va
5 - Bolts
i
o
pr
cum
r
fo
❑ Qty. 2
en
ng
t.
yi Co
satelettronica
❑ 9 Nm ht. Cop py
rig
rig ht
6 - Remote release mecha‐ py by
co Vo
nism
by lksw
cted agen
Prote AG.
⇒ page 117
7 - Operating rod to locking lev‐
er

1.1.5 Assembly overview - middle guide rail
Note
Only the right side is shown. The left side is similar. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
1 - Bolts uthor eo
a ra
❑ Qty. 5 ss c
ce
❑ 8 Nm le
un
pt
an
d
itte
y li
2 - Bolts
erm
ab
ility
❑ At front and rear.
ot p
wit
is n
❑ 2 Nm
h re
ole,
spec
3 - Cover
t to the co
4 - Clip
❑ Qty. 7
❑ Qty. 9 for long wheel‐
rrectne
satelettronica
base
s
5 - Guide rail
s o
cial p
f
inform
⇒ page 126
mer
atio
m
6 - Spacer
o
n
c
i
or
n
❑ Intermediate piece, for
thi
e
allocation refer to ⇒
t
sd
iva
o
Electronic parts cata‐
pr
cum
r
fo
logue (ETKA)
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Sliding door 101

1.1.6 Assembly overview - middle guide rail, long wheelbase
Note
1 - Guide rail
❑ Removing and installing agen
AG. Volkswagen AG d
oes
⇒ page 126 Volksw not
gu
d by ara
e
2 - Bolts horis nte
eo
ut
❑ Qty. 7 ss a ra
c
ce
❑ 8 Nm
le
un
pt
an
d
itte
3 - Bracket
y li
rm
ab
pe
ility
4 - Blind rivet nut
ot
wit
, is n
❑ Qty. 7
h re
hole
❑ Insert with pop rivet nut
spec
satelettronica
pliers - V.A.G 1765B-
es, in part or in w
t to the co
5 - Spacer
❑ Intermediate piece, for
rrectness of i
allocation refer to ⇒
Electronic parts cata‐
l purpos
logue (ETKA)
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.2 Removing and installing inner door seal


Note

teed.
Removing
Rep. gr. 70 ; Trims, interior; Overview of fitting wlocations
agen
AG. Vo-lkswagen AG d
oes
trims, interior . yV
o lks not
gu b ara
ed
tho
ris nte
e or
au ac
Installing ss
ce
e
nl
pt
du
satelettronica
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
1.3 Removing and installing outer door seal

m
at
om
io
Removing
n
c
in t
or
his
e
– Pull outer door seal -1- off door edge.

at
do
priv
– Unclip outer door seal -1- on lower edge of sliding door.

um
for
en
ng
t.
yi
Installing
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted
– Fit outer door seal on corner -arrow- first when installing.
agen
Prote AG.
Note
Before installing outer door seal -1-, check clips -2-, and renew
them as necessary.
1. Sliding door 103

1.4 Removing and installing sliding door

⇒ “1.4.1 Removing and installing sliding door”, page 104
⇒ “1.4.2 Renewing sliding door”, page 105
1.4.1 Removing and installing sliding door

AG. Volkswagen AG d
Removing lksw
agen oes
not
Vo gu
by
– Remove door arrester ⇒ page 115ri.sed ara
nte
ho eo
– Close sliding door -1-. aut ra
ss c
ce
le
– Unclip cover for bolts on hinge fitting from sliding door trim.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
The bolts -2- remain in the opening of the sliding door.
t to the co
ic.
satelettronica
rrectne
– Open sliding door.
ss
– Pull hinge fitting out of sliding door.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
– Guide lower roller guide -1- in -direction of arrow- out of lower

t.
yi Co
op
guide rail. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

n AG. Volkswagen AG
– Lower sliding door -2- at front until upper
olksroller
wage guide -1- can does n
ot g
be removed from guide channel ind-direction
by
V of arrow-. ua
r e an
ris tee
Installing tho or
au ac
ss
ce
le
un
pt
an
– Adjust hinge fitting ⇒ page 105 .
d
itte
y li
rm
ab
Then, check operation of sliding door.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4.2 Renewing sliding door
rrectness of i
l purpos
Note
nform
ercia
♦ To keep the number of parts down to a minimum, sliding doors

are often supplied in the »basic version« only ⇒ Electronic
m
a
com
t
parts catalogue (ETKA) .
io
satelettronica
n in
r
te o
♦ In this case, we recommend that a unique template is made
thi
s
iva
from the damaged part in the workshop.
do
r
rp
cum
fo
♦ When making a template, use e.g. beads on the damaged part
en
ng
t.
yi
as reference points.
Co
Cop py
ht. rig
rig ht
py by
Sliding door without cut-out for impact bar: co Vo
by lksw
cted agen
Prote
– Position template on new part with reference points, and se‐
AG.
cure it with commercially available adhesive tape.

– Thickness of template must be taken into account when posi‐
tioning template before new part is painted.
– Transfer shape to new part, remove template, and cut out
aperture for impact bar using suitable workshop equipment.
– Deburr edges.
1.5 Adjusting sliding door

1. Sliding door 105

♦ Protective caps - T10250-
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
Note aut or
ac
ss
ce
e
nl
♦ Vehicle must be standing on its wheels when adjustments are
pt
du
an
performed.
itte
y li
erm
ab
♦ Only the adjustment for the right sliding door is described. The
ility
ot p
adjustment of the left sliding door is similar.
wit
, is n
satelettronica
h re
♦ The sliding door is adjusted correctly if the shut lines/gaps are
hole
spec
uniform all around, the door is not too deep or too high and all
es, in part or in w
contours align when it is closed ⇒ Body Repairs; Rep. gr. 00 ;
t to the co
Gaps/shut lines; Body - centre and rear .
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Sequence of operations
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1- Adjusting hinge fitting ⇒ page 106

2- Adjust striker pin ⇒ page 107 .
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3- Adjusting lower roller guide ⇒ page 107

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4- Adjusting upper roller guide ⇒ page 108

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7- Adjusting rubber buffer ⇒ page 111
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Prote AG.
Adjusting hinge
• Height of sliding door is incorrect at rear.
• Sliding door is not aligned with outer contour of C-pillar.
Adjusting height of hinge:
Note
In area of the C-pillar, height of the sliding door relative to the roof
is adjusted via the adjustable hinge pin.

– Loosen nut -3-.

– Using hex socket, turn hinge pin -2- on underside in order to
adjust height -arrows A- of hinge -4-.
– Upon completion of the adjustment procedure, tighten nut
-3- to specified torque.
Adjusting length of hinge:
– Remove cover for bolts and for hinge fitting ⇒ General body
repairs, interior; Rep. gr. 70 ; Rear door trims; Removing and
installing rear door trim .
– Close sliding door -5-, and loosen bolts -1- working from inside
the vehicle.
– Have a second mechanic lift sliding door -5- and push it into
correct position along a straight line -arrows B-.
satelettronica
Note
To avoid damage to the guide rail cover during closing, the hinge
must be pushed in direction of the C-pillar.
– Upon completion of the adjustment procedure, tighten bolts

-1- to specified torque.
Specified torques
AG. Volkswagen AG d
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– Adjust striker pin -2- so that the recess in the lock with rotary
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WARNING
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The sliding door must not be raised or pushed down by the

striker pin.
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Specified torques
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• Sliding door is not aligned with outer contour of driver's door. Prote AG.
1. Sliding door 107

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– Loosen bolts -1- on locking pegs at top and bottom -2-.
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– If fitted, unclip roller guide trim -3- upwards from roller guide.
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– The height of the sliding door -arrow A- can be adjusted by
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Lower roller guide 20 Nm
Adjusting upper roller guide
• Sliding door is not aligned with outer contour of driver's door
at top.
– Loosen bolts -1- on locking pegs at top and bottom -2-.

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– After adjusting, readjust locking pegs ⇒ page 109 .
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WARNING
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Upper roller guide must not scrape on body.
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Specified torques
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Upper roller guide 9 Nm
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Adjusting sliding door locking pegs
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Prote AG.
♦ To adjust the locking pegs of the sliding door on the right side of the vehicle, use the green protective caps
- T 10250- .
♦ To adjust the locking pegs of the sliding door on the left side of the vehicle, use the red protective caps - T
10250- .
♦ When adjusting the locking pegs, make sure that the locking pegs point towards the interior of the vehicle.
1. Sliding door 109

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– Loosen bolts -1- until the upper and lower locking pegs -2- are
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lision with any components. Prote AG.
– Now, closes sliding door completely. The locking pegs -2- are
adjusted automatically in this way.
– Open sliding door and tighten bolts -1-.
– Remove protective caps -3- from locking pegs -2-.
– By closing sliding door again carefully, check whether locking
pegs -2- run centrally into catch plates -4-.
WARNING

locking pegs! Nor must locking pegs be used to adjust flush‐
ness.

Adjusting sliding door locking pegs, as of calendar week 32, 2016
Note
The locking pegs for the sliding door have been modified. There‐
fore, the protective caps - T 10250- are not required any longer.
– Loosen bolts -2- of locking pegs -1- just far enough so that
locking pegs -1- do not move autonomously.
– Slowly close sliding door. Locking peg -1- is then centred by
catch plate -3-.
Specified torques
♦ ⇒ “1.1.2 Assembly overview - sliding door locking and nrelease
AG. Volkswagen AG d
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Adjusting rubber buffers. db ara
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Adjusting striker pin, for high sliding door only
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– Striker pin -1- can be moved horizontally and vertically by

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– Tighten striker pin -1-.
WARNING

striker pin.
Specified torques
Striker pin 50 Nm
1. Sliding door 111

1.6 Removing and installing striker pin agen

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1.6.1 Removing and installing striker pin
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Removing
Installing
1.6.2 Removing and installing striker pin and


Note
Removal and installation are described only for the right side. The removal and installation procedure for the
left-hand side is basically the same.
satelettronica
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1. Sliding door 113

Removing
– Remove rear right side panel moulded trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Trims, interior; Removing and
installing side trim .
– Remove striker pin -1- from C-pillar.
– Remove motor -3- from opening in inner C-pillar.
Installing
Install in reverse order of removal,
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Specified torquesed by V ua
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Componentauth Specified torque or
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Striker 20 Nm
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1.7 Removing and installing lower roller
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Prote AG.
is basically the same.
♦ Removal and installation is described for version with no ar‐
rester. The removal and installation of lower roller guide with
arrester is similar.
Removing
– Remove door arrester ⇒ page 115 .
– Remove lower roller guide -1-.
– Bowden cable must be detached on roller guides with arrester.
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview – sliding door”, page 95

1.8 Removing and installing door arrester

Note
For reasons of clarity, the sliding door is shown removed.
satelettronica
Removing
– Remove striker pin -1- for arrester. AG. Volkswagen AG d
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Specified torques ss
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Bolts -2- 4 Nm
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1.9 Removing and installing hinge

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Removing
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– Remove lower sliding door trim ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Rear door trims; Removing and installing
rear door trim .
– Remove roller guide trim ⇒ page 328 .
1. Sliding door 115


Further removal is only possible with the assistance of a second
mechanic who holds the sliding door.
AG. Volkswagen AG d
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– Push hinge fitting -1- in -direction of arrow- out of roller guide
-2-.
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Installing
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Specified torques
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♦ ⇒ “1.1.1 Assembly overview - sliding door roller guides”, page

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Prote AG.
Note
Removal and installation are described only for the right door lock.
The removal and installation of the left door lock is similar.

Removing
rear door trim .
– Remove door lock -3- from sliding door.
– Unclip Bowden cable -2- from door lock -3-.
Installing
Specified torques
Door lock 18 Nm
AG. Volkswagen AG d
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1.11 Removing and installing sliding door re‐ by gu
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The removal and installation sequence is only for the right remote
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rear door trim .
– Remove lock cylinder and exterior door handle ⇒ page 121 .
– Remove door lock ⇒ page 116 .
1. Sliding door 117

– Remove sliding door contact module ⇒ page 97 .

– Unclip childproof lock -1- from sliding door -2- using a screw‐
driver.
– Pull childproof lock -1- out of sliding door -2- in
-direction of arrow-.
AG. Volkswagen AG d
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– Guide remote release mechanism -1- downwards in
-direction of arrow-. Swing remote release mechanism out of
sliding door.

– Disengage Bowden cable -2- from Bowden cable guide in

-direction of arrow-.
– Unclip Bowden cable -2- from clip -3-.
– Remove remote release mechanism -1- from sliding door.
Installing
Before closing sliding door, check operation of lock and release
components.
Specified torques
♦ ⇒ “1.1.3 Assembly overview - sliding door remote release
mechanism”, page 99
1.12 Removing and installing contact module
satelettronica
and contact strip
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1. Sliding door 119

satelettronica
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Removing contact strip
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– Unscrew bolts -2- and pull contact strip -1- out of B-pillar -3-.
rrectness of i
– Separate electrical connectors.
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Removing contact module

– Unscrew bolts -5- and pull contact module -4- out of sliding
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Note
cally the same.
Removing
rear door trim .
– Loosen bolt -1- (do not unscrew completely) on mounting
bracket -2- using socket wrench TORX T20 - T 10072- .
– Pull lock cylinder -2- at right angles out of mounting bracket of

door handle.
Installing
1. Sliding door 121

– Insert door handle -2- from outside into mounting bracket.

– Push opening mechanism -arrow- back when doing this.
Then check function with sliding door open.

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Removing
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Specified torques
AG.

Mounting bracket 3 Nm
1.15 Removing and installing interior door

handle

Note
cally the same.
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Prote AG.
1. Sliding door
Removing
– Remove knob -1- and trim -2- for interior door handle ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Rear door trims;
Removing and installing rear door trim .
– Remove interior door handle -3- with operating rod -4- up‐
wards from remote release mechanism -6-.
Installing
Then check function with sliding door open.
Specified torques
♦ ⇒ “1.1.4 Assembly overview - interior operating mechanism”,
page 100
1.16 Removing and installing upper guide rail

satelettronica
AG. Volkswagen AG d
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AG. Volkswagen AG d
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Removing
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– Remove sliding door ⇒ page 104 .

hole
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– Detach moulded headliner in front and middle areas, and low‐

t to the co
er it ⇒ General body repairs, interior; Rep. gr. 70 ; Roof trims;

Removing and installing moulded headliner .
rrectness of i

– Unscrew nut -2-.
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– Remove guide rail -1-.

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Installing
m
at
om

ion
c
in t
or
Specified torques
his
ate
do
priv

cum
for
en
ng
t.
Upper guide rail Cop
yi
8 Nm Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Sliding door 125

1.17 Removing and installing middle guide

rail
Note
The removal and installation sequence is only for the right guide
rail. The removal and installation of the left guide rail is similar.
Removing
Note
♦ For reasons of clarity, the sliding door is shown removed.

♦ The removal and installation procedures may have to be modified slightly depending on model variants.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Remove tail light cluster ⇒ Electrical system; Rep. gr. 94 ;

r
te o
thi
Tail lights; Removing and installing tail light cluster .

s
iva
do
r
rp

um
fo

en
ng
t.
yi
lower sliding door trim .
Co
Cop py
t. rig
gh ht
yri by
126
op Vo
by c lksw
Rep. gr.58 - Rear doors, door components Prote
cted AG.
agen
– Unscrew bolts -2- at front and rearVfrom cover -3-.

olkswa AG. gen AG
agen do
– Close sliding door (notVocompletely,
lksw just far enough) until
es n
ot g cover
y
-3- can be unclipped
se
d without damage.
b ua
ran
ri tee
ho
– Pull cover -3-auin
t direction of -arrow- out of side panel. or
ac
ss
– First, unscrew bolt -1- from C-pillar.
ce
le
un
pt
an
d
itte
– Close sliding door until door lock engages in first detent of
y li
erm
ab
striker pin.
ility
ot p
– Then, unscrew remaining bolts -1-.
wit
is n
h re
ole,
– Guide the guide rail -5- out of hinge.
spec
Installing
t to the co
rrectne
Note
ss o
♦ Before installing the guide rail -1-, make sure that the intermediate piece (zinc) - AKL 381 035 50- -6- is
cial p
f in
adapted using workshop equipment before bonding to the side panel.
form
mer
satelettronica
atio
♦ Cut intermediate piece (zinc) - AKL 381 035 50- -6- to size as follows: “cut outer edge round, cut out centre
om
piece, and assemble in a circle”.
n
c
i
or
n thi
e
♦ Before installing cover -3-, check securing parts -4- and renew as necessary.
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Sliding door 127

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Then check function of sliding door. co Vo
by lksw
cted agen
Prote
Specified torques
AG.
♦ ⇒ “1.1.5 Assembly overview - middle guide rail”, page 101

2 Electrically operated sliding door

⇒ “2.1 Assembly overview - electric sliding door”, page 129
⇒ “2.2 Removing and installing outer door seal with roll-back
function”, page 134
⇒ “2.3 Removing and installing sliding door”, page 135
⇒ “2.4 Removing and installing striker pin with power latching
motor”, page 137
⇒ “2.6 Removing and installing motor to open right sliding door
V323 ”, page 139
⇒ “2.7 Removing and installing guide rail with roller bearing”, page
141
⇒ “2.8 Removing and installing upper guide rail with reader coil”,
page 144
⇒ “2.9 Removing and installing upper roller guide with transpond‐
er”, page 146
satelettronica
⇒ “2.10 Removing and installing lower roller guide”, page 147
⇒ “2.11 Removing and installing right electric sliding door sender
unit G481 ”, page 148
2.1 Assembly overview - electric sliding

door
. Volkswagen AG
wa gen AG does
⇒ “2.1.1 Assembly overview - components for electrically Voperat‐
olks not
gu
ed sliding door”, page 129 ed
by ara
nte
is
or eo
⇒ “2.1.2 Assembly overview - guide rail with rollerau bearing”,
th page ra
131 ss c
ce
le
un
pt
⇒ “2.1.3 Assembly overview - upper roller guide with transpond‐
an
d
itte
er”, page 131
y li
rm
ab
pe
ility
⇒ “2.1.4 Assembly overview - lower roller guide”, page 132
ot
wit
, is n
⇒ “2.1.5 Assembly overview - wiring for electric sliding door op‐
h re
hole
eration”, page 133
spec
es, in part or in w
2.1.1 Assembly overview - components for electrically operated sliding door

t to the co
rrectness of i
Note
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Electrically operated sliding door 129

lkswage es n
Vo ot g
Transporter 2016ed➤ by ua
ran
ir s
General bodythrepairs, exterior - Edition 10.2019
o tee
or
au ac
ss
1 - Motor to open right sliding
ce
e
nl
pt
door - V323-
du
an
itte
y li
erm
ab
⇒ page 139
ility
ot p
wit
, is n
2 - Middle guide rail with rollers
h re
hole
spec
⇒ page 141
es, in part or in w
t to the co
3 - Striker pin with sliding door
power latching motor - V324-
rrectness of i
⇒ page 137
l purpos
4 - Guide rail with upper reader

coil
nf
ercia
o
rm
m
atio
⇒ page 144
om
n in
c
5 - Upper roller guide with

or
thi
e
transponder
t
sd
iva
o
r
rp
cu
❑ Wiring is integrated in
o
m
f
anti-trapping protection.
en
ng
t.
satelettronica
yi Co
op
❑ Removing and installing C py
t. rig
⇒ page 146
gh ht
pyri by
Vo
co lksw
by
6 - Anti-trapping protection Prote
cted AG.
agen
with sensor
⇒ page 134
⇒ page 114
8 - Right electric sliding door
sender unit - G481-
⇒ page 148
9 - Sliding door
10 - Door arrester
11 - Right sliding door control unit - J731- / left sliding door control unit - J558-

2.1.2 Assembly overview - guide rail with roller bearing
Note
1 - Guide rail with roller bearing

⇒ page 141
2 - Bolts
❑ Qty. 5
❑ 8 Nm
3 - Zinc foil
❑ Zinc intermediate piece;
allocation ⇒ Electronic
parts catalogue (ETKA)
4 - Blind rivet nut
satelettronica
❑ Qty. 5
❑ Install using pop rivet
nut pliers - V.A.G
1765B-
lkswage es n
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byV ua
d ran
ir se tee
tho
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
2.1.3 Assembly overview - upper roller guide

with transponder
ss o
cial p
1 - Upper roller guide with transponder ⇒ page 146

inform
mer
2 - Specified torque for bolts: 20 Nm

atio
m
3 - Wire for pinch protection

o
n
c
i
or
n thi
e
4 - Adjustment screw ⇒ page 108

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.1.4 Assembly overview - lower roller guide

⇒ page 147
2 - Bolts
❑ Qty. 3
❑ 20 Nm
3 - Door joint seal
⇒ page 102
4 - Cable grommet
❑ Anti-pinch protection for
wiring
satelettronica
lkswage es n
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byV ua
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.1.5 Assembly overview - wiring for electric sliding door operation
Note
Only the right sliding door is shown. The left sliding door is similar.
1 - Upper roller guide with

transponder
❑ For electric sliding door.
⇒ page 146
2 - Sliding door
⇒ page 135
❑ Anti-pinch protection for
wiring
satelettronica
❑ For wire of roller guide
5 - Wire for pinch protection
❑ Roll-back function is in‐
tegrated into seal
6 - Upper roller guide wiring
❑ The wiring for the upper
AG. Volkswagen AG d
roller guide with trans‐ lksw
agen oes
not
ponder is routed and se‐ byV
o gu
ara
cured beneath the outer rised
nte
o
door seal. aut
h eo
ra
ss c
7 - Door joint seal
ce
le
un
pt
❑ For vehicles with elec‐

an
d
itte
y li
tric sliding door opera‐

erm
ab
tion and power latching.

ility
ot p
wit
❑ Roll-back function is in‐

is n
h re
tegrated into seal

ole,
spec
❑ The wiring for the upper

roller guide with trans‐

t to the co
ponder is routed and se‐

cured beneath the outer
door seal.
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.2 Removing and installing outer door seal with roll-back function
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
satelettronica
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Removing
f
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
♦ Removal and installation are described only for the right side. The removal and installation procedure for
Prote AG.
the left-hand side is basically the same.

♦ The seal with integrated wire cannot be removed without becoming damaged.
♦ The wire for the upper roller guide with transponder is bonded in the seal.
♦ The seal only has one connecting cable. The 2nd cable is an item supplied with the roller guide.

– Removing upper roller guide with transponder ⇒ page 146
– Pull outer door seal -1- off edge of sliding door, and unclip it
from lower edge of sliding door.

– If the outer door seal -1- is renewed, the wiring for roller guide
-4- must be detached from outer door seal -1-.
– Pull wire out of sliding door.
Installing
– If the outer door seal -1- is renewed, the wiring for roller guide
-4- must be routed under outer door seal -1-.
– Secure wiring for roller guide -4- with rubber adhesive at top
and bottom to prevent slipping in outer door seal -1-.
2.3 Removing and installing sliding door

⇒ “2.3.1 Removing and installing sliding door with electrical con‐
trols”, page 135
⇒ “2.3.2 Renewing sliding door”, page 137
2.3.1 Removing and installing sliding door

with electrical controls
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ Removal and installation are only for the right sliding door with
spec
electrical controls. Removal and installation of the left sliding

es, in part or in w
t to the co
door with electrical controls are similar.

♦ Various versions of buttons for deactivating the sliding door
with electrical controls are possible.
rrectness of i
♦ The sliding door with electrical controls will not open as easily
l purpos
once deactivated.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Deactivate electrical controls of sliding door by pressing button
-1- in dash panel.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Close sliding door -1-.
wit
, is n
h re
– Unclip cover on hinge fitting from sliding door trim.
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -4- from sliding door with electrical controls
-1-.
satelettronica
rrectness of i
– Slide roller bearings -3- back in guide rail -2-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Further dismantling requires the assistance of a second mechan‐ Prote
cted AG.
agen
ic.
– Guide roller guide -1- in -direction of arrow- out of lower guide
rail.

– Lower sliding door -2- at front until upper roller guide -1- can
be removed from upper guide rail -arrow-.
Installing
Specified torques
Roller bearing 65 Nm agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
2.3.2 Renewing sliding door
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ To keep the number of parts down to a minimum, sliding doors
hole
spec
are often supplied in the »basic version« only ⇒ Electronic
es, in part or in w
t to the co
satelettronica
♦ In this case, we recommend that a unique template is made
from the damaged part in the workshop.
rrectness of i
♦ When making a template, use e.g. beads on the damaged part
l purpos
as reference points.
nf
ercia
Sliding door without cut-out for impact bar:
orm
m
– Position template on new part with reference points, and se‐
atio
m
cure it with commercially available adhesive tape.

o
n in
or c
thi
e
– Thickness of template must be taken into account when posi‐

t
sd
iva
tioning template before new part is painted.
o
r
rp
cu
o
m
f
– Transfer shape to new part, remove template, and cut out

en
ng
t.
yi Co
aperture for impact bar using suitable workshop equipment. t. Cop py
rig
gh ht
– Deburr edges. pyri by
Vo
co lksw
by
cted agen
2.4 Removing and installing striker pin with
Prote AG.


Note
The removal and installation sequence is only for the right door
striker pin with power latching system. Removal and installation
of the left door striker pin with power latching system is similar.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
Removing
in t
or
his
ate
– Remove rear right side panel moulded trim ⇒ General body

do
priv

um
for
installing side trim .

en
ng
t.
yi Co
op py
– Disconnect connector -2-. t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
– Remove striker pin -1- from C-pillar.
– Remove motor -3- from opening in inner C-pillar.
Installing

Specified torques
Striker 20 Nm

satelettronica
Note
♦ The removal and installation sequence is only for the right door
arrester. Removal and installation of the left door arrester is
similar.
Removing
– Take off door arrester -2-. agen
AG. Volkswagen AG d
oes
olksw not
V
Installing d by gu
ara
rise nte
o
Install in reverse orderauof
t removal, observing the following:
h eo
ra
ss c
Specified torques
ce
e
nl
pt
du
an
itte

y li
erm
ab
Door arrester 8 Nm
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
2.6 Removing and installing motor to open

t to the co
right sliding door - V323-

rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
139
AG.
2. Electrically operated sliding door
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
cally the same.
wit
, is n
h re
hole
satelettronica
Removing
spec
es, in part or in w
• Sliding door is closed.

– Remove rear right side panel trim ⇒ General body repairs, t to the co
interior; Rep. gr. 70 ; Trims, interior; Removing and installing
rrectness of i
rear side panel trim, Multivan .

l purpos
– If installed, release 2nd heat exchanger and fold to side ⇒

Heating, air conditioning system; Rep. gr. 87 ; Climatronic -
air conditioning system with automatic regulation; Removing
nform
ercia
and installing 2nd heat exchanger .

m
at
om

on
c
in t
or
– Push right sliding door control unit - J731- -1- downwards to‐
his
ate
gether with bracket -2- and remove from D-pillar in direction of

do
priv
-arrow-.
um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Separate electrical connector -3- on control unit.

– Remove motor to open right sliding door - V323- -1-. AG. Volkswagen AG d
agen oes
lksw not
Installing d by Vo gu
ara
rise nte
Install in reverse order of removal, observing the
utho following: eo
ra
s a c
Specified torques s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Motor for opening sliding door 8 Nm
t to the co
rrectne
2.7 Removing and installing guide rail with
roller bearing
ss
satelettronica
o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
cally the same.
Removing
– Remove lower trim of sliding door ⇒ General body repairs,
interior; Rep. gr. 70 ; Rear door trim panels; Removing and
installing lower trim of sliding door .


– Slide roller bearings -3- back in guide rail -2-.
ic.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove guide rail with roller bearing -1-.

Note
♦ Fit the guide rail drive onto hexagon of the sliding door opening motor ensuring a positive fit.
♦ When removing, make sure to pull the guide rail off the sliding door opening motor in a straight line.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
satelettronica
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installing
Before installing guide rail with roller bearing -1-, intermediate
piece (zinc) - AKL 381 035 50- -3- must be adapted using work‐
shop equipment before bonding to side panel.
Cut intermediate piece (zinc) - AKL 381 035 50- -3- to size as
follows: “cut outer edge round, cut out centre piece and assemble
in a circle”.
– Push middle guide rail with roller bearing -1- in a straight line
onto hexagon of sliding door opening motor.
– Screw in bolts -2-, and tighten them to specified torque.
Then check function of sliding door.

Specified torques
Bolts for securing roller guide to slid‐ 65 Nm
ing door
Bolts securing guide rail to body 8 Nm wage
es n
olks ot g
yV ua
2.8 Removing and installing upper guide rail d b ran
ir se tee
o
with reader coil th or
au ac
ss
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
a
com
tion in
Note
r
te o
thi
s
iva
do
The removal and installation sequence is only for the right guide
r
rp
rail with reader coil. The removal and installation of the left guide cum
fo
en
g
rail with reader coil is similar.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
satelettronica
wit
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guide rail ⇒ page 146 .
– Remove B-pillar upper trim (Multivan/Shuttle) ⇒ General body
installing B-pillar trim .
– Pull coil -5- out of clips -3-.
– Unscrew nut -4-.
– Remove guide rail -2-.
Installing
Specified torques
Guide rail 8 Nm

2.9 Removing and installing upper roller

guide with transponder
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♦ The removal and installation sequence is only for the right roll‐
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hole
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left roller guide with transponder is similar.
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♦ The wiring to the upper roller guide with transponder is routed
through the outer door seal of the sliding door. That is why the
upper roller guide with transponder and the outer door seal
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can not be removed without damage.
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– Remove upper roller guide with transponder -1- and wiring for
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roller guide -4- with outer door seal -3- from the sliding door.
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– Guide wire out of sliding door.

Installing
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Specified torques
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♦ ⇒ “2.1.3 Assembly overview - upper roller guide with trans‐

ponder”, page 131
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2.10 Removing and installing lower roller

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♦ ⇒ “2.1.4 Assembly overview - lower roller guide”, page 132
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2.11 Removing and installing right electric

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Note
The removal and installation sequence is only for the right sender
unit. The removal and installation of the left sender unit is similar.

Removing
– Unscrew nut -3- (qty. 2).
– Detach right electric sliding door sender unit - G481- -1-.
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Sender unit 8 Nm
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⇒ “3.1 Assembly overview – sliding door”, page oris150
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page 152 c
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⇒ “3.6 Removing and installing centre stop”, page 155
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⇒ “3.7 Removing and installing guide wedge - wedge guide”, page
156
3.1 Assembly overview – sliding door
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⇒ “3.1.1 Assembly overview - locking and release components for
ss
high sliding door”, page 150
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⇒ “3.1.2 Assembly overview - emergency release”, page 152
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3.1.1 Assembly overview - locking and release components for high sliding door
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⇒ page 104 ss
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⇒ page 154
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⇒ page 155
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5 - Guide wedge - wedge guide
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⇒ page 156
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3. Sliding door - high 151

3.1.2 Assembly overview - emergency release
1 - Emergency release AG. Volkswagen AG d

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5 - Bowden cable
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❑ To remote release
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3.2 Removing and installing inner door

seals
Note

teed.

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– Detach any adjacents trims ⇒ General body repairs, interior;
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spec
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– The inner door seal -1- must be positioned with the vulcanised
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3.3 Renewing pre-seal pyri by
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Note
♦ Bonding surfaces must be free of dirt, dust, grease and other

contaminants and must be dry.
♦ Remove backing only immediately before installation.
– Pull protective film -2- off pre-seal -1-.

– Position pre-seal -1- on roof frame.
– Press on pre-seal -1- firmly.
3.4 Removing and installing additional lock


Removing
– Unclip Bowden cable from emergency release ⇒ page 154 .
satelettronica
– Remove additional lock -1- with grommet -4- from sliding door.
– Unclip Bowden cable -3- from additional lock -1-.
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Install in reverse order of removal, observing the following: thoris nte
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Additional lock 8 Nm
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3.5 Removing and installing manual release
hole
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mechanism
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Removing p by
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– Remove lower sliding door trim ⇒ General body repairs, inte‐ Prote AG.
– Unclip door lock Bowden cable ⇒ page 116 .
– Unclip remote release Bowden cable ⇒ page 117 .
– Remove manual release mechanism -1- from sliding door.
– Unclip Bowden cable for additional lock -3- from manual re‐
lease mechanism -1-.
Installing
Specified torques
♦ ⇒ “3.1 Assembly overview – sliding door”, page 150
3.6 Removing and installing centre stop


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Removing by
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– Unscrew bolts -2-. hor eo
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– Remove centre stop -1- from sliding door. s
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When opening sliding door, centre stop -1- and lower stop must
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contact C-pillar simultaneously ⇒ page 97 .
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Centre stop 20 Nm
inform
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3.7 Removing and installing guide wedge - atio

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♦ Pop rivet pliers - VAS 5072-
Removing
Guide wedge
– Remove guide wedge -1- from sliding door.
Wedge guide
satelettronica
– Drill out pop rivets -2-.
– Remove wedge guide -1-.
Installing AG. Volkswagen AG d
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⇒ “4.1 Assembly overview - cab door”, page 158
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page 159
h re
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⇒ “4.3 Removing and installing inner door seals”, page 160
es, in part or in w
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⇒ “4.4 Removing and installing cab door”, page 161
⇒ “4.5 Adjusting cab door”, page 163
rrectness of i
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⇒ “4.7 Removing and installing door hinge”, page 165

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⇒ “4.9 Removing and installing impact bar”, page 166
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⇒ “4.11 Removing and installing door handle”, page 168
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4.1 Assembly overview - cab door
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Note

1 - Cab door
⇒ page 161
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5 - Door arrester
⇒ page 166
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6 - Bolts
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❑ Qty. 2
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❑ 6 Nm
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7 - Bolt
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❑ Qty. 2
❑ 20 Nm +90°
11 - Bolts
❑ Qty. 2
❑ 20 Nm +90°
4.2 Assembly overview - door handle and

door lock
Note
Minor differences may be encountered during repair work, de‐

pending on vehicle model.
4. Cab door - double cab 159

1 - Locking button
2 - Trim collar
❑ Clipped into cab door
3 - Locking rod
4 - Bowden cable
❑ From door lock to interi‐
or operating mechanism
⇒ page 170
6 - Bolt
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⇒ page 167
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9 - Cover
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spec
10 - Key
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t to the co
❑ Changing battery on re‐
mote control ⇒ page 92
❑ Changing battery on key
rrectness of i
with light ⇒ page 92
l purpos
11 - Door handle
nform
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⇒ page 168
m
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12 - Bolt
ion
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❑ 4.5 Nm
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13 - Door lock
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14 - Bolts C py
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4.3 Removing and installing inner door

seals

Note

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trims, interior .
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Installing
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4.4 Removing and installing cab door
sd
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Note
Removal and installation are described for left cab door. Removal and installation of right cab door are similar.

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General body repairs,th exterior - Edition 10.2019
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Removing
– Remove double cab trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, insulation; Door trims; Removing and in‐
stalling double cab trim .
– Disconnect connectors (if fitted).
– Guide wire out of cab door.
– Loosen bolts -2- on top and bottom (do not unscrew them
completely).
ic.
– Remove cab door -1-.
Installing
– Adjust cab door ⇒ page 163 .
Specified torques
♦ ⇒ “4.1 Assembly overview - cab door”, page 158

agen
AG. Volkswagen AG d
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Adjusting cab door
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Special
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– Cab door is adjusted by loosening bolts -2- on upper door

hinges -1- and lower door hinges -3-.

– Cab door is adjusted correctly if gaps/shut lines are even all

around with door closed, the door does not project in or out
too far and the contours -arrows- align.
Note
♦ The cab door must lock fully when closing without any addi‐
tional force being required and must not have any play.
♦ The cab door must not be pushed up or down due to striker
pin adjustment.
The following can be adjusted at the striker pin:

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– Adjust striker pin -1- in such a way that the recess of the door s
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lock with rotary latch is centred relative to the striker pin -1-
nl
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when it engages.
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Specified torques
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Striker 20 Nm
nform
mercia
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4.6 Removing and installing striker pin ion

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Prote AG.
Note
Removal and installation are described only for the right door
striker pin. Removal and installation of the left striker pin are sim‐
ilar.

Removing
Installing
4.7 Removing and installing door hinge

♦ Torque wrench - V.A.G 1331- AG. Volkswagen AG d
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Removal and installation are described for the left door hinges.
Removal and installation of the right door hinges are similar.
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Removing
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The removal requires the help of a second mechanic.
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– Unscrew bolts -2- on upper hinge -1-.

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– Unscrew bolts -2- on lower hinge -3-.

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– Adjust cab door ⇒ page 163 .
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Specified torques


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– Unscrew bolt -3- from B-pillar.
hole
spec
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– Remove door arrester -4- from cab door -1-.
Installing
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Specified torques
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4.9 Removing and installing impact bar

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Note
Removal and installation of the impact bar are described for the
left side. Removal and installation of the impact bar on the right
side are similar.

Removing
– Remove impact bar -3- from cab door -1-.
Installing
AG. Volkswagen AG d
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♦ If the cab door is renewed,
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and rear for the impact
s au bar of the cab door must be reworked ra
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using workshop equipment.
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♦ Refer to old cab door for mounting hole positions.
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Specified torques
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Impact bar 20 Nm
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Note

Removing
– Pull door handle -1- in -direction of arrow-.
– While pushing on socket wrench TORX T20 - T 10072- , un‐
screw bolt -2- until lock cylinder -3- can be pulled out.
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Unscrewing the bolt rise too far may result in the locking bar separat‐
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Door handle must rest only lightly against outer door panel.
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– Screw bolt -2- into mounting bracket using socket wrench
TORX T20 - T 10072- .
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The door handle engages in the lock cylinder with an audible click.
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During installation, the lock cylinder must be pressed against the

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outer door panel. The door handle just rests lightly against the
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outer panel of door.

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4.11 Removing and installing door handle
Prote AG.

♦ Assembly tool - T10118-
Note
♦ The removal and installation sequence is only for the left door
handle. The removal and installation of the right door handle
is similar.

Removing
– Release clip -1- from door handle -2-.
AG. Volkswagen AG d
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Installing
– Guide assembly tool - T 10118- through the opening on the
inside of the door panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool - T10118- in spring -arrow A-.
– Attach spring in door lock by pulling assembly tool - T10118-
-arrow B-.
Note
Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden
cable to the door handle later.
– Swing door handle -2- into door.
satelettronica
– Engage clip -1- in door handle -2-.
AG. Volkswagen AG d
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♦ Press door handle -2- against outer panel of door when as‐
th eo
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♦ Clip -1- must engage audibly in door handle -2-.
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– Install lock cylinder ⇒ page 167 .

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It is essential that the function then be checked with the door

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hole
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the door cannot be opened.

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bracket
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Removing
– Remove door lock ⇒ page 171 .


– Push mounting bracket -3- slightly towards rear, and remove
it from cab door -1-.
Installing
Specified torques
Mounting bracket 4.5 Nm

satelettronica
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Note
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♦ Removal and installation are described only for the left door
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lock. The removal and installation of the right door lock is sim‐
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h re
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spec


t to the co
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Removing
– Remove trim for double cab ⇒ General body repairs, interior;
Rep. gr. 70 ; Rear door trims; Removing and installing rear
door trim .
– Remove door handle ⇒ page 168 .
– Unscrew locking button -6- from locking rod -1-.
– Unscrew bolts -5- for door lock -3-.
– Guide door lock -3- downwards.
– Unclip Bowden cable -2- from door lock -3-.
– If fitted, disconnect connector -4- from door lock -3-.
Installing
After installation, check operation with cab door open.
Specified torques
Door lock 20 Nm

5 Wing doors AG. Volkswagen AG d

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⇒ “5.1 Assembly overview - wing door”, by
V page 173
ol not
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⇒ “5.2 Assembly overview - doorhor arrester with opening angle of eo
ut
250°”, page 177 ss a ra
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⇒ “5.3 Assembly overview - door components”, page 178
nl
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⇒ “5.4 Removing and installing wing door seal”, page 180
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⇒ “5.5 Removing and installing inner seal of wing door”,
wit
page 182
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⇒ “5.6 Removing and installing wing door”, page 182
spec
es, in part or in w
⇒ “5.7 Adjusting wing door”, page 184
t to the co
⇒ “5.8 Removing and installing upper striker pin”, page 190
rrectness of i
⇒ “5.9 Removing and installing lower striker pin”, page 191
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⇒ “5.10 Replacing wing door”, page 192

⇒ “5.11 Removing and installing wing door hinges”, page 192
nf
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⇒ “5.13 Installing stop in wing door for door arrester with opening
o
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angle of 250°”, page 195

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⇒ “5.14 Removing and installing wing door locks”, page 198
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⇒ “5.15 Removing and installing release lever”, page 201
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⇒ “5.16 Removing and installing childproof lock”, page 203
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⇒ “5.17 Removing and installing latch carrier”, page 203
op Vo
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Prote AG.
⇒ “5.18 Removing and installing interior door handle”,
page 204
⇒ “5.19 Removing and installing exterior door handle”,
page 204
⇒ “5.20 Removing and installing subframe”, page 205
⇒ “5.21 Removing and installing light strip”, page 207
5.1 Assembly overview - wing door

⇒ “5.1.1 Assembly overview – right wing door”, page 173
⇒ “5.1.2 Assembly overview - rear left wing door”, page 175
⇒ “5.1.3 Assembly overview - wing door hinges”, page 176
5.1.1 Assembly overview – right wing door
5. Wing doors 173

1 - Right rear wing door

⇒ page 182
2 - Upper hinge
⇒ page 192
3 - Bolts
❑ Qty. 2
❑ 20 Nm
4 - Bolts
❑ Qty. 3
❑ 20 Nm
5 - Bolts
❑ Qty. 3
❑ 20 Nm
6 - Door arrester
satelettronica
⇒ page 194
❑ Door arrester with an
opening angle of 250°
⇒ page 195 .
7 - Bolts
❑ Qty. 2
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8 - Lower hinge ised b ara
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❑ Removingaut
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⇒ page
ss 192 c
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9 - Bolts
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❑ 20 Nm
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10 - Bolts
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❑ 20 Nm
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11 - Plugs
❑ Qty. 3
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5.1.2 Assembly overview - rear left wing door

❑ Removing and installing AG. Volkswagen AG d
⇒ page 182 agen oes
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❑ Adjusting ⇒ page 184sed b ara
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2 - Upper hinge au
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⇒ page 192
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3 - Bolts
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❑ 20 Nm
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4 - Bolts
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❑ Qty. 3
❑ 20 Nm
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5 - Bolt
❑ Qty. 3
satelettronica
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❑ 20 Nm
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6 - Door arrester
m
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⇒ page 194
on
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❑ Door arrester with an
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7 - Bolts
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❑ Qty. 2
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8 - Lower hinge
⇒ page 192
9 - Bolts
❑ Qty. 2
❑ 20 Nm
10 - Bolt
❑ Qty. 3
❑ 20 Nm
11 - Plugs
❑ Qty. 3
5. Wing doors 175

5.1.3 Assembly overview - wing door hinges
Note
1 - Left rear wing door

2 - Bolts
❑ Qty. 2
❑ 20 Nm
3 - Bottom hinge 180°
⇒ page 192
4 - Bolts
❑ Qty. 2
❑ 20 Nm
satelettronica
5 - Top hinge 180°
⇒ page 192
6 - Bottom hinge 250°
⇒ page 192
7 - Bolts
❑ Qty. 2
❑ 20 Nm
8 - Bolts n AG. Volkswagen AG do
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⇒ page 192
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5.2 Assembly overview - door arrester with opening angle of 250°
Note
1 - Door arrester stop

2 - Bolts
❑ Qty. 2
AG. Volkswagen AG d
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4- Left rear wing
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5 - Side panel
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6 - Magnetic insert
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❑ Hole distance 34 mm
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7 - Stop - side panel
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spec
8 - Pin wrench - 3212-
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5. Wing doors 177

5.3 Assembly overview - door components

⇒ “5.3.1 Assembly overview - locking and release components,
wing doors, standard roof”, page 178
⇒ “5.3.2 Assembly overview - locking and release components,
wing doors, high roof”, page 179
⇒ “5.3.3 Assembly overview - subframe”, page 180
5.3.1 Assembly overview - locking and release components, wing doors, stand‐
ard roof
1 - Upper striker pin

❑ Removing and installing agen
AG. Volkswagen AG d
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⇒ page 190 Volksw not
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2 - Upper right lock horis tee
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❑ Removing and au
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⇒ page 198
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3 - Operating lever
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⇒ page 201
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4 - Lower right lock
hole
spec
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⇒ page 198
5 - Lower striker pin t to the co
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⇒ page 191
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6 - Handle trim
nform
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⇒ page 207
m
at
7 - Latch carrier
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⇒ page 203
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⇒ page 204
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9 - Exterior door handle with
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lock cylinder
⇒ page 204
lock cylinder
⇒ page 208
10 - Subframe
11 - Lower left lock
12 - Childproof lock
13 - Upper left lock

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5.3.2 Assembly overview - locking and release components, wing doors, high roof
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⇒ page 198
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2 - Subframe
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⇒ page 205
3 - Lower left lock
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⇒ page 198
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4 - Upper right lock

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⇒ page 198
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5 - Operating lever
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⇒ page 201
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6 - Lower right lock
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5. Wing doors 179

5.3.3 Assembly overview - subframe
1 - Subframe
❑ With carrier and interior
release mechanism.
⇒ page 205
2 - Nuts
❑ Qty. 2
❑ 20 Nm
❑ For carrier and exterior
door handle.
4 - Mounting plate
5 - Bolts AG. Volkswagen AG d
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❑ 8 Nm ut
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❑ For upper lock
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8 - Pull rod
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9 - Bolt
❑ 8 Nm
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5.4 Removing and installing wing door seal

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♦ During series production, a sealant is applied to the wing door
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Removing

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trims, interior .
– Pull wing door seal -1- off body flange.
Installing
– Align wing door seal -1- with joint -arrow a- approx. 300 mm
from vehicle centre.
Note
Note colour code -arrow b- to facilitate installation.
– Press wing door seal -1- onto body flange.
5. Wing doors 181

5.5 Removing and installing inner seal of

wing door olks
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– Pull wing door interior seal -2- off right wing door au
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– First fit upper and lower parts of inner door seal -2-.
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– Compress or stretch inner door seal -2- as appropriate. Then,
fit inner door seal onto flange of wing door -1-. hole
spec
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satelettronica
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5.6 Removing and installing wing door
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Note
Removal and installation are described only for right wing door. Removal and installation of left wing door are
similar.

satelettronica
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Removing
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– Remove trim for wing door ⇒ General body repairs, interior;

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door trim . tion in

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– Disconnect connectors of installed electrical components (if

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– Lever out upper and lower plugs -2- from wing door -4-. Prote
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– Loosen upper and lower bolts -1- in wing door apertures -4-
(do not unscrew bolts completely).
ic.
– Now, unscrew bolts -1- completely and remove wing door
-4-.
Installing
– Adjust wing door -4- ⇒ page 184 .
5. Wing doors 183

Specified torques
♦ ⇒ “5.1 Assembly overview - wing door”, page 173
5.7 Adjusting wing door

satelettronica
Note
♦ Basic wing door adjustment is carried out by adjusting the upper and lower hinges -3-.
♦ The wing doors are adjusted via the upper lock -2-, the upper striker pin -1- and the lower striker pin -4-.
See below for step-by-step guide on wing door adjustment.
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Basic setting of wing door ⇒ page 186 .
Adjust upper striker pin ⇒ page 189 .
Adjust lower striker pin ⇒ page 189 .
Adjust upper lock ⇒ page 190 .
5. Wing doors 185

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Basic adjustment of wing door ss c
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♦ Basic adjustment is described for left wing door only. Basic
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adjustment of right wing door is similar.
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♦ In order to perform basic adjustment of wing door, vehicle must
be positioned on its wheels.
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♦ Wing door is adjusted correctly if (when door is closed) gaps/
shut lines are even all around, if door is not too deep and does
rrectne
not stand proud, and if all contours align.
♦ Adjustment work should be performed on the right-hand wing
ss
door first and then on the left-hand door. The aid of a second
o
cial p
f i
mechanic is required.
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♦ Ensure even gaps around tail light.
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♦ Match sealing line by adjusting door hinges or bending fitted
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♦ Checking and adjusting gaps/shut lines ⇒ Body Repairs; Rep.

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♦ After installing or adjusting, carry out corrosion protection
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Upper hinge
– The wing door can be adapted to fit in upper area by loosening
bolts -1- on upper hinge -2- (do not unscrew completely).
Lower hinge
– The wing door can be adapted to fit in lower area by loosening
bolts -3- on lower hinge -4- (do not unscrew completely).
5. Wing doors 187

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Transporter 2016 ➤ wage
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– First, align right wing door according
au
t
to outer contour ra
c
ss
-arrows a- with help of second mechanic.
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an
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to outer contour -arrows b- with help of second mechanic.
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– After adjustment on upper hinge -1-, tighten bolts -2-.

– After adjustment on lower hinge -4-, tighten bolts -3-.

Note
Carry out corrosion protection measures on wing door hinge and securing bolts after assembly and adjustment
work.
Specified torques
Adjusting upper striker pin
Note
♦ Adjustment work should be performed on the right-hand wing

door first and then on the left-hand door.
♦ The area between the striker pin must be covered by the insert.
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– Remove roof end strip ⇒ General body
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gr. 70 ; Trims, insulation; Roof trims;
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Removing and installing c
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– Loosen bolts -2- and slide upper striker pin -1- in over-sized
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– Adjust striker pin -1- in such a way that the recess of the lock
hole
spec
with rotary latch is centred relative to the striker pin -1- when
es, in part or in w
it engages.
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– Close wing door and make sure adjustment has been carried
out correctly.
rrectness of i
• Wing doors must lock properly when closing without any ad‐
l purpos
ditional force being required and must not have any play.
• Wing door must not be raised or pressed down.
nform
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Specified torques
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Upper striker pin 20 Nm

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Adjusting lower striker pin

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Adjustment work should be performed on the right-hand wing
AG.
5. Wing doors 189

– Remove lock carrier cover ⇒ General body repairs, interior;

Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling lock carrier cover .
– Loosen bolts -2- and slide lower striker pin -1- in over-sized
holes.
– Adjust striker pin -1- in such a way that the recess of the door
lock with rotary latch is centred relative to the striker pin -1-
when it engages.
– Close wing door and make sure adjustment
agen has been carried
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• Wing doors must lock properly tho
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s a and must not have any play.
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Specified torques
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Lower striker pin 20 Nm
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Adjusting upper lock
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Note
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♦ To improve clarity, upper lock cap is not depicted.
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♦ Adjustment is carried out for left lock only. Adjustment of the

right upper lock is similar.
nf
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♦ Adjustment work should be performed on the right-hand wing orm

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– Close wing door and make sure adjustment has been carried
out correctly.
• Upper lock must lock properly when closing without any addi‐
tional force being required and must not have any play
Specified torques
Upper lock 20 Nm
5.8 Removing and installing upper striker

pin

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– Undo and remove bolts -2- and remove upper striker pin -1-.
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– Adjust upper striker pin -1- ⇒ page 189 .
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Striker 20 Nm
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5.9 Removing and installing lower striker pin

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5. Wing doors 191

Removing
– Remove lock carrier cover ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling lock carrier cover .
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– Undo and remove bolts -2- and remove lower striker pin V-1-.
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– Adjust lower striker pin -1- ⇒ page 189 .
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Specified torques
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Striker 20 Nm
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5.10 Replacing wing door
To keep the number of parts down to a minimum, replacement
rrectness of i
parts are often supplied in the basic version (e.g. without aperture
for rear window wiper etc.).
l purpos
satelettronica
• Produce hole for rear window wiper before passing on for
painting.
nform
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In this case, it is recommended that the workshop produces a

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template from the damaged part.
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Using body saw - V.A.G 1523A- , make a cut a section out of the
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Note
Note thickness of template when positioning template and mark‐

ing location of holes before painting new part.
5.11 Removing and installing wing door hing‐

es

Note
Removal and installation are described only for right hinges of

wing door. Removal and installation of left hinges of wing door are
similar.
Note
Removal and installation of wing door hinges is only possible with aid of second mechanic. While one person
replaces the parts, the other must hold the wing door.
satelettronica
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– Lever out plug -4- from wing door.
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– Undo bolts -1- and -3- and remove upper hinge -2-.
Lower hinge:
– Lever out lower plug -5- from wing door.
5. Wing doors 193

– Undo bolts -8- and -6- and remove lower hinge -7-.
Installing
– Adjust wing door ⇒ page 184 .
Specified torques n AG. Volkswagen AG do
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♦ ⇒ “5.1 Assembly overview - wing by Vdoor”, page 173
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5.12 Removing and installing door arrester autho
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– Unscrew bolts -3- from D-pillar and remove door arrester -1-.
Installing
Specified torques

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5.13 Installing stop in wing door for door ar‐
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t to the co
arrester stop is not fitted.
♦ The threaded nut for the door arrestor stop threads is included
rrectness of i
with the spare parts.
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♦ The following description describes process for the holes.

♦ Following description applies to left wing door. Assembly of
nform
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right wing door is similar.

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– Mark point -3- on inside of wing door according to dimensions
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1 - Dimension a = 35 mm
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❑ from lower edge of wing
door -1- to point -3-
5. Wing doors 195

satelettronica
AG. Volkswagen AG d
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The threaded nut for the door arrester stop is visible on the inside.
nform
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– Drill through nut from inside to outside using a 4.0 mm drill bit.
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– From the outside, countersink hole -1- until the thread is com‐
pletely visible using a 10 mm drill bit.
– Mark point -2- from centre of hole -1- according to dimension
-a-.
Dimension a = 14 mm
– At point marked -2-, drill a 6.0 mm hole using drill bit.
Note
Seal the 18 mm hole on the inside of the wing door with a plug - 191 971 908 B- .
5. Wing doors 197

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olksw not
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Transporter 2016 ➤ ut ho eo
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5.14 Removing and installing wing door locks
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⇒ “5.14.1 Removing and installing upper right wing door lock”,
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⇒ “5.14.2 Removing and installing upper left wing door lock”, page
spec
198
es, in part or in w
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⇒ “5.14.3 Removing and installing lower right wing door lock”,
page 199
rrectness of i
⇒ “5.14.4 Removing and installing lower left wing door lock”, page
200
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5.14.1 Removing and installing upper right
nform
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wing door lock

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Removing
door trim .
– Pull cover cap -3- off upper lock -1-.
– Unclip Bowden cable -4- from release lever ⇒ page 201 .
– Unscrew bolts -2- and pull upper lock -1- out of wing door.
– Unclip Bowden cable -4- from upper lock -1-.
Installing
• During assembly, ensure that Bowden cable -4- is clipped in
place correctly.
• Before installing the wing door trim, check the function of the
release components.
– Adjust upper lock -1- ⇒ page 190 .
Specified torques
Upper lock 20 Nm
5.14.2 Removing and installing upper left wing

door lock

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– Unscrew bolts -2- and pull upper lock -1- out of wing door.
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– Unclip Bowden cable -4- from upper lock -1-.
Prote AG.
Installing
• During assembly, ensure that Bowden cable -4- is clipped in
place correctly.
release components.
– Adjust upper lock -1- ⇒ page 190 .
Specified torques
Component Specified torques
Upper lock 20 Nm
5.14.3 Removing and installing lower right wing

door lock
5. Wing doors 199

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– Undo and remove bolts -2- and pull lower lock -1- out of wing
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– Detach connector -3- from lower lock -1-.
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Installing
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• During assembly, ensure that operating rod -4- is clipped in
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rrectness of i
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Specified torques
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Removing
door trim .
– Unclip operating rod -4- from carrier from the inside of vehicle
⇒ page 203 .
– Undo and remove bolts -2- and pull lower lock -1- out of wing
door.
– Detach connector -3- from lower lock -1-.
Installing
• During assembly, ensure that operating rod -4- is clipped in
place correctly.
release components.
Specified torques
satelettronica
Lower lock 20 Nm
5.15 Removing and installing release lever

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5. Wing doors 201

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Removing
door trim .
– Unclip operating rod -3- and Bowden cable -4- from operating
lever -1- from inside of vehicle.
– Unscrew bolt from -2- handle recess -1- and remove release
lever -5- from outside.
Installing
– Locate handle recess -1- in wing door and bolt to release lever
-5-.
– During assembly, ensure that operating rod -3- and Bowden
cable -4- are clipped in place correctly.
release components.
Specified torques
Operating lever 1.2 Nm

5.16 Removing and installing childproof lock

Removing
– Unclip childproof lock -2- from right wing door -1- using a
screwdriver.
– Pull childproof lock -2- out of right wing door -1-.
Installing
– Press childproof lock -2- into aperture in right wing door -1-.
• Childproof lock -2- must audibly engage.
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5.17 Removing and installing latch carrier
es, in part or in w
t to the co
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Note Prote AG.
The removal and installation procedures may have to be modified

slightly depending on variations in equipment.
5. Wing doors 203

Removing
door trim .
– Detach connector -5- from assembly carrier -1- and remove
cable ties -6-.
– Unclip locking rod for interior door handle -3-, and unclip pull
rod for interior door handle -7- from latch carrier -2-.
– Unclip pull rod for lower lock -4- and pull rod for lock cylinder
relay lever -9- from latch carrier -2-.
– Unclip Bowden cable for upper lock -8- from latch carrier -2-.
– Unscrew bolts -arrows-.
– Unclip pull rod for exterior door handle -10- from latch carrier
-2-.
Installing
During assembly, ensure that all pull rods, the operating rod and
satelettronica
the Bowden cable are clipped in place correctly.
Before installing the wing door trim, check the function of the re‐
lease components. gen AG
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Component au
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5.18 Removing and installing interior door

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– Detach assembly carrier ⇒ page 205 .

– Unclip locking rod -3- and pull rod -4- from latch carrier.
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– Disengage locking hooks -arrows- from catches on assembly

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carrier -2- using a screwdriver.

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– Pull interior operating mechanism -1- with locking rod -3- and
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pull rod -4- out of assembly carrier -2-.

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5.19 Removing and installing exterior door

handle

Removing
– Remove carrier ⇒ page 203 .
– Undo and remove bolts -2- and remove exterior door handle
-1- from wing door.
Installing
satelettronica
Specified torques
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Component Specified by torque
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Exterior door handle 8thoNm
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5. Wing doors 205

satelettronica
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door trim .
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– Disconnect connector -3- from assembly carrier -1-, and re‐

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move cable ties.

– Unclip pull rod for lower lock -4- and pull rod for lock cylinder
nf
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relay lever -6- from latch carrier.

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– Unclip Bowden cable for upper lock -7- from latch carrier.
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– Unscrew nuts -2- from assembly carrier -1-.

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– Unscrew bolts -5- and -9-.

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– Remove assembly carrier -1- from wing door. Prote
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Installing
During assembly, ensure that all pull rods, the operating rod and
the Bowden cable are clipped in place correctly.

lease components.
Specified torques
♦ ⇒ “5.3 Assembly overview - door components”,
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5.21 Removing andorinstalling
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Special tools and workshopsequipment
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♦ Torque wrench - V.A.G 1783- e
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Removing
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door trim .
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– Remove interior operating mechanism ⇒ page 204 .

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– Unscrew bolts of exterior door handle ⇒ page 204 .

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– Disconnect connector -2-, and remove light strip -1- from out‐ by c lksw
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Installing
Specified torques
Light strip 4 Nm
5. Wing doors 207


Removing
– Remove exterior door handle ⇒ page 204
– Fold protective plate -1- upwards in directionagof
en -arrow
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– Lift clip -2- slightly with a screwdriver
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– Using a screwdriver, carefullyapress
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-5- in -direction of arrow b- off
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– Press lock cylinder -4- out of exterior door handle -1- in
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– Carefully press lock cylinder relay lever -4- in
nform
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-direction of arrow- onto exterior door handle -3-.

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– Carefully push lock cylinder -5- in -direction of arrow- into ex‐
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– Lock cylinder -5- must audibly engage in exterior door handle

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– Push clip -2- downwards into exterior door handle -3-.
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– Close guard plate -1-.
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– Install exterior door handle -3- ⇒ page 204 .
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release components.

60 – Sunroof
1 Sliding sunroof
⇒ “1.1 Assembly overview - sliding sunroof”, page 209
⇒ “1.2 Removing and installing glass panel”, page 211
⇒ “1.3 Adjusting sunroof panel”, page 212
⇒ “1.4 Renewing panel seal”, page 214
⇒ “1.5 Removing and installing wind deflector”, page 214
⇒ “1.6 Removing and installing sliding headliner”, page 215
⇒ “1.7 Removing and installing sliding/tilting sunroof drive”, page
215
⇒ “1.8 Adjusting drive for sliding/tilting sunroof (zero position)”,
page 216
⇒ “1.9 Removing and installing tilt mechanism for sliding sunroof”,
page 217
satelettronica
⇒ “1.10 Removing and installing carrier unit”, page 217
⇒ “1.11 Operating without current”, page 219
1.1 Assembly overview - sliding sunroof
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1. Sliding sunroof 209

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Transporter 2016
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General body
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repairs, exterior - Edition 10.2019 ra
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1 - Glass panel for sliding/tilting
un
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sunroof (toughened safety d
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glass)
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⇒ page 211
h re
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spec
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2 - Panel seal
t to the co
❑ Renewing ⇒ page 214
3 - Sliding headliner
rrectness of i
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⇒ page 215
4 - Slide
nform
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❑ For sliding headlining

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5 - Bellows
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❑ For covering guide plate
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6 - Water channel
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❑ Is removed together
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7 - Water channel seal
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8 - Water hose
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Prote AG.
9 - Bolt
❑ 2 Nm
10 - End piece
❑ Use Butyl adhesive
sealing cord AKL 450
005 05 to seal.
11 - Carrier unit
⇒ page 217
❑ U-frame (with guide
channels) - if necessary, guide channels should be lubricated using only special grease ⇒ ETKA as
otherwise functions may be impaired.
12 - Electric drive
❑ Adjusting drive ("0" position) ⇒ page 216 .
13 - Bolts
❑ Bolts are microencapsulated and must always be renewed after removal
❑ 3.5 Nm
14 - Crank for emergency operation
❑ The hexagon key is located with the vehicle tool kit in the luggage compartment.
15 - Cover
16 - Wind deflector
17 - Retaining strap
18 - Wind deflector mounting with spring
19 - Bolts
❑ Bolts are microencapsulated and must always be renewed after removal
❑ 4.5 Nm
210 Rep. gr.60 - Sunroof

20 - Guide plate
❑ Cannot be renewed individually
21 - Slide with cable
❑ Cannot be renewed individually
22 - Water channel slide
1.2 Removing and installing glass panel

Removing
– Push sliding headliner to rear.
– Tilt up sliding/tilting sunroof.
– Unclip bellows -1-, first from lower guide rail -2- and then from
glass panel -3-.
satelettronica
– Lift out sliding/tilting sunroof upwards.
Installing
Panel must be installed in the zero position (panel closed).
Note
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The screws are microencapsulated and must always be renewed.
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Zero position au
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Guide pins -1- must align with markings -arrows- on guide plates.
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If this is not the case, adjust parallel running ⇒ page 214 .
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– Insert sliding/tilting sunroof from above.
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– Tighten bolts -1- only slightly. First adjust glass panel height,
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and then tighten bolts completely.
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♦ ⇒ “1.1 Assembly overview - sliding sunroof”, page 209
es, in part or in w
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1.3 Adjusting sunroof panel
nform
mercia
⇒ “1.3.1 Adjusting height of sliding/tilting sunroof glass panel”,
at
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page 212
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⇒ “1.3.2 Checking parallel running of glass panel”, page 213

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⇒ “1.3.3 Adjusting parallel running of glass panel”, page 214
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1.3.1 Adjusting height of sliding/tilting sunroof
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– Sliding/tilting sunroof zero position OK. Prote AG.
– Push sliding headliner to rear.

– Unclip bellows -1-, first from lower guide rail -2- and then from
glass panel -3-.
– Loosen bolts of glass panel.
– Close glass panel, open panel and close again (adhere strictly
to sequence to achieve a correct adjustment).
– Adjust height of glass panel at front and rear on both sides as
described below.
Front panel adjustment:

a = 0…1 mm lower than roof edge
Arrow = direction of travel

Rear panel adjustment:

b = 0…1 mm higher than roof edge
Arrow = direction of travel
– Tighten glass panel bolts.
Always tighten left and right sides of glass panel symmetrically.

– Clip bellows -1-, first into lower guide rail -2- and then into glass
panel -3-.
Specified torques
satelettronica
AG. Volkswagen AG d
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1.3.2 Checking parallel running of glass panel d byV
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– Push sliding headliner to rear.utho eo
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– Tilt up sliding/tilting sunroof. s
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– Unclip bellows -1-, first from lower guide rail -2- and then from an
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– Move glass panel to zero position.

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Guide pins -1- must align with marking on guide plates.

nform
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If this is not the case, adjust parallel running ⇒ page 214 .

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1.3.3 Adjusting parallel running of glass panel
Note
The parallel running adjustment can only be undertaken when the

drive and solar panel are removed (zero position).
AG. Volkswagen AG d
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– Removing sunroof drive ⇒ page 215 b. y V ol not
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– Install drive in “0” position (marks thorin view window must align). eo
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Guide pins -1- must align with marking
s on guide plates.
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1.4 Renewing panel seal
rrectne
– Removing glass panel for sunroof ⇒ page 211 .
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– Pull seal -1- off glass panel.
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– Press seal into groove in glass panel -2-.
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To ease fitting of seal, coat panel edge with a soapy solution.
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1.5 Removing and installing wind deflector
– Open sunroof completely.
– Unscrew bolts -1- from left and right retaining straps.
– Move wind deflector in -direction of arrow- to vertical position.
– Remove wind deflector towards rear from mountings -2-.
Installing
Installation is carried out in reverse order.

1.6 Removing and installing sliding headlin‐

er
Removing
Sliding/tilting sunroof glass panel removed and sliding/tilting sun‐
roof unit in “closed position”.
– Move sliding panel forwards.
– Push sliding headliner to one side.
– Lever slide -1- (from front to rear) out of guide channel using
a screwdriver.
– Remove sliding headliner upwards.
Installing
– Insert sliding headliner in roof aperture.
– Fit slide -1- (engaged in sliding headliner) into guide channels
on one side. Then fit the slides on the opposite side into the
guide channels.
satelettronica
AG. Volkswagen AG d
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1.7 Removing and installing sliding/tilting by
Volksw not
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Special tools and workshop equipment required ss c
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♦ Torque wrench 210 Nm - V.A.G 1783-
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Removing
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– Remove console in moulded headliner ⇒ General body re‐

o
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c
pairs, interior; Rep. gr. 70 ; Compartments/covers; Removing

or
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and installing storage compartment in moulded headliner .

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Motor change - preselection switch recognition:

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• Remove or install drive for tilting/sliding sunroof glass panel
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Prote AG.
only when sunroof is closed ("0" position ).
• Engine and ignition off, remove key and open door.
If this is not the case, the drive may not correctly recognise the
preselection switch and does not run to the correct positions.
This will be apparent if the sunroof stops approx. 10 cm before
the fully closed position when the switch is in the “closed” position.

– Unscrew bolts -arrows-.

– Pull off from drive for sliding/tilting roof -1-.
– Disconnect connector -2- for sliding/tilting roof drive.
Installing
• The bolts for the sliding/tilting sunroof drive are microencap‐
sulated and must always be renewed.n AG. Volkswagen A ge G do
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• Tighten bolts -arrows-.by Volk ot g
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• Then check function.
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⇒ page 216
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Specified torques
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1.8 Adjusting drive for sliding/tilting sunroof
spec
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satelettronica
The zero position needs to be set if:
rrectness of i
♦ a new drive for sliding/tilting sunroof has been installed
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♦ the drive has been removed in a position other than zero po‐
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♦ the sliding/tilting sunroof has been opened or closed manually.

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♦ The drive for the sliding/tilting sunroof forms one component

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The following points are essential to ensure correct zero position Prote AG.
of the drive:
• the drive for sliding/tilting sunroof is installed
• electrical wiring of the preselector for sliding/tilting sunroof (ro‐
tary switch in sliding sunroof) has been connected with ignition
switched off ⇒ page 217
• The glass panel has been fitted in the “Roof closed” position.
Height adjustment ⇒ page 212 .

Adaption of drive for sliding/tilting sunroof

– Close sunroof by hand.
– Install sliding sunroof motor.
– Switch on ignition.
– Press switch until motor comes to a halt.
– Release switch briefly.
– Wait 1 to 2 seconds, then press switch again and hold it until
motor comes to stop automatically.
Note
In the meanwhile, the sliding sunroof is moved back and com‐

pletely closed again.
– Release rotary switch.

– Adaption is complete.
satelettronica
1.9 Removing and installing tilt mechanism
for sliding sunroof G. Volkswage
nA n AG d
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– Remove console in moulded Vol
ks headliner ⇒ General body
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t gre‐
by ua
pairs, interior; Rep.isgr.
ed 70 ; Compartments/covers; Removing ran
and installing storage
uthor
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– Release threes catches on back of light unit in direction of
ce
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-arrow-.
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– Push out rotary switch from the front side by hand.

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1.10 Removing and installing carrier unit

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Removing cted agen
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– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Roof trims; Removing and installing moulded
headliner .
– Pull water drain hoses -arrows- off carrier unit -1-.
– Disconnect connector on drive -3-.
– With the aid of a second mechanic, remove carrier unit from
vehicle.
Installing
– With the help of a second mechanic, fit carrier unit -1- to roof
frame.
– Start bolts.
– Align carrier unit -1- with glass panel in roof aperture.
– Tighten bolts for carrier unit -1-, starting at sliding/tilting sun‐
roof drive -3- and moving towards rear, alternating between
left and right-hand sides.

– Check routing of lines of electrical consumers in roof, and re‐

store them as necessary.
– Connect water drain hoses -arrows-.
– Connect connector for drive -3-.
Specified torques
Carrier unit 8 Nm
1.11 Operating without current

– Remove lights and operating unit ⇒ Electrical system; Rep.
gr. 96 ; Controls; Removing and installing sunroof button .
– Insert hexagon key into bolt of drive.
– Push hexagon key upwards -arrow-.
– The bolt will be pressed a few millimetres inwards -a-.
– The sliding/tilting sunroof panel can only be moved in this po‐
sition.
satelettronica
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AG. Volkswagen AG d
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Transporter 2016 ➤ ut
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General body repairs, exterior - Edition 10.2019ss c
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2 Water drain hoses
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⇒ “2.1 Cleaning water drain hoses”, page 220
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2.1 Cleaning water drain hoses
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spec
es, in part or in w
t to the co
⇒ “2.1.1 Cleaning front water drain hoses”, page 220
⇒ “2.1.2 Cleaning rear water drain hoses”, page 222
rrectness of i
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♦ Cleaning and fitting tool - VAS 6620-
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2.1.1 Cleaning front water drain hoses

satelettronica
AG. Volkswagen AG d
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The front water drain hoses run through the A-pillars and end at
an
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the engine bulkhead. Cleaning is done from the sunroof panel

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aperture.
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Use cleaning and insertion aid - VAS 6620- for cleaning.

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2. Water drain hoses 221

2.1.2 Cleaning rear water drain hoses
satelettronica
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The rear water drain hoses run through the D-pillars and end in
t to the co
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.
rrectness of i
Note
l purpos
Use cleaning and insertion aid - VAS 6620- for cleaning.

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AG. VoGeneral
lkswagen Abody
G do repairs, exterior - Edition 10.2019
agen es n
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61 – Convertible roof, hardtop, canopy
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1 Convertible top
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⇒ “1.1 Assembly overview - canopy frame with canopy”,
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page 223
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⇒ “1.2 Contact corrosion”, page 225
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spec
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1.1 Assembly overview - canopy frame with
t to the co
canopy
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⇒ “1.1.1 Canopy frame with canopy on vehicle”, page 223
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⇒ “1.1.2 Convertible roof frame with canopy and fastening com‐

ponents”, page 225
nform
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1.1.1 Canopy frame with canopy on vehicle

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1 - Convertible roof frame with
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canopy
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2 - Bolts
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3 - Nuts opyri
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❑ 3 on each hoop by c lksw

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❑ 20 Nm
4 - Cross strut
❑ Qty. 4
5 - Pop rivets
❑ Insert using pop rivet pli‐
ers - VAS 5072-
❑ Qty. 2
❑ Secured with 2 pop riv‐
ets
7 - Stay tube
❑ For front of canopy at
bottom
8 - Bush
❑ Qty. 2
❑ For front of tailgate
9 - Bolts
❑ Qty. 2
10 - Stay tube
❑ For front of canopy
❑ Secured on each side
with one pop rivet
11 - Nuts
❑ Qty. 2
❑ 20 Nm
12 - Front strut
❑ Qty. 2
1. Convertible top 223

olks
wage - Edition 10.2019 es n
o V t gu
by ara
❑ Secured with 4 opop ed
ris rivets on each side nte
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13 - Tube s au ra
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❑ For canopy on outside e
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❑ Secured at the front and rear with 3 pop rivets
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❑ For vehicles with wheelbase of 3,400 mm
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❑ For vehicles with wheelbase of 3,000 mm, shorten to 2,578 mm
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❑ Shorten double cab to 2,190 mm
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14 - Link plate
t to the co
❑ Front right or rear left
❑ Secured with 5 pop rivets
rrectness of i
15 - Bracing bow cross piece
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❑ Secured with 3 pop rivets on each side
nform
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16 - Link plate
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❑ Left or rear right
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❑ Fastened with 9 blind rivets -5-
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❑ For canopy
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❑ Secured at the front and rear with 2 pop rivets t. Cop py
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❑ For vehicles with wheelbase of 3,000 mm, 3,400 mm and double cab
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Prote AG.
224 Rep. gr.61 - Convertible roof, hardtop, canopy

1.1.2 Convertible roof frame with canopy and fastening components
1 - Canopy
❑ Material: PVC
❑ For vehicles with wheel‐
base of 3,000 mm,
3,400 mm and double
cab
2 - Tube
❑ For canopy on outside
❑ For vehicles with wheel‐ AG. Volkswagen AG d
base of 3,400 mm agen oes
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❑ For vehicles with wheel‐ ed b ara
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base of 3,000 mm, thor eo
shorten to 2,578ssmm
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❑ Shorten double cab to
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2,190 mm
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3 - Tubes
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❑ For canopy
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base of 3,000 mm,
spec
3,400 mm and double
t to the co
cab
4 - Link plate
rrectne
❑ Front right or rear left
5 - Link plate
ss o
❑ Left or rear right
cial p
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6 - Bracing bow cross piece
mer
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7 - Plugs
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8 - Cross strut
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9 - Front strut
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10 - Stay tube Prote AG.
❑ For front of canopy

❑ Qty. 2
12 - Stay tube
❑ For front of canopy at bottom
1.2 Contact corrosion

The add-on parts, side boards and tail boards of the dropside
model are made from aluminium.
When these parts are installed, special care must be taken re‐
garding contact corrosion.
Contact corrosion can occur if unsuitable fastening elements
(bolts, nuts, washers and pop rivets) are used.
1. Convertible top 225

For this reason, only connecting elements with a special surface

coating (Dacromet) haveswbeen AG. Volkswagen AG d
agen fitted. oes
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These elements scan
ed be recognised by their green colour.
ua
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If there is anyut doubt about the suitability of parts, a general rule
or
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is to use new parts.
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Note
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♦ Use only genuine parts!
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♦ Accessories must be approved by Volkswagen AG!
spec
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♦ Damage resulting from contact corrosion is not covered by the
t to the co
warranty.
rrectness of i
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nform
mercia
satelettronica
at
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or
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for
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t.
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Cop py
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by
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Prote AG.
226 Rep. gr.61 - Convertible roof, hardtop, canopy

AG. Volkswagen AG d
agen oes
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V
d by gu
ara Transporter 2016 ➤
ise nte
thor General body erepairs,
or exterior - Edition 10.2019
au ac
ss
ce
e
63 – Bumpers
nl
pt
du
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1 Bumper, front
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⇒ “1.1 Assembly overview - bumper cover”, page 227
spec
es, in part or in w
⇒ “1.2 Removing and installing bumper cover”, page 230
t to the co
⇒ “1.3 Repairing bumper cover”, page 234
rrectness of i
1.1 Assembly overview - bumper cover
l purpos
⇒ “1.1.1 Assembly overview - bumper cover”, page 227

⇒ “1.1.2 Assembly overview - add-on parts”, page 229
nform
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⇒ “1.1.3 Assembly overview - reinforcement”, page 230

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1.1.1 Assembly overview - bumper cover
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♦ Minor differences may be encountered in respect of bumper cover, depending on vehicle model.
t. C rig
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♦ Different versions, for allocation refer to ⇒ Electronic parts catalogue (ETKA) .
co Vo
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Prote AG.
1. Bumper, front 227

1 - Front bumper cover

⇒ page 230
2 - Spreader clip agen
AG. Volkswagen AG d
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❑ Qty. 3 by
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3 - Clip ut
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4 - Reinforcement s
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⇒ page 230
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5 - Guide profile
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❑ Left and right
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⇒ page 13
es, in part or in w
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6 - Spreader clip
❑ Left and right
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7 - Bolts
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satelettronica
❑ Bolted to wheel housing
nform
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liner.
m
❑ 2 Nm at
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8 - Bolts
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❑ 2 Nm
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Prote AG.
228 Rep. gr.63 - Bumpers

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ise nte
thor General body repairs,
eo exterior - Edition 10.2019
au ra
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1.1.2 Assembly overview - add-on parts
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Note
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1 - Bumper cover
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❑ satin black
s
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⇒ page 230
cial p
f inform
2 - Trim
mer
atio
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❑ Left and right

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❑ For vehicles without fog
or
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light
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3 - Reinforcement
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❑ Left and right
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❑ Engaged in front bump‐
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❑ Can only be detached
agen
Prote AG.
with front bumper cover
removed ⇒ page 234
4 - Radiator grille
⇒ page 308
5 - Bumper cover
❑ Primed
⇒ page 230
6 - Ventilation grille
❑ Left and right
❑ Can only be removed
with front bumper cover
removed
7 - Cover strip
❑ Left and right
8 - Trim
❑ Left and right
❑ For vehicles without fog light
9 - Trim strip
10 - Centre air intake grille
❑ Can only be removed with front bumper cover removed
11 - Frame
❑ For vehicles with ACC
12 - Towing eye cap
❑ Engaged in bumper cover
13 - Badge

1.1.3 Assembly overview - reinforcement
1 - Reinforcing member
⇒ page 230
2 - Bolts
❑ 6 Nm
satelettronica
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1.2 Removing and installing bumper cover

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⇒ “1.2.1 Removing and installing bumper cover”, page 230

es, in part or in w
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⇒ “1.2.2 Removing and installing reinforcement”, page 232
1.2.1 Removing and installing bumper cover

rrectness of i
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satelettronica
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Removing
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♦ The removal and installation procedures for front bumper cover may have to be revised slightly depending
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♦ The bumper cover is removed together with the radiator grille.
by lksw
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Prote AG.

– Unclip spreader clips -2-.

– Unclip clip -3-.
– Unscrew bolts -5- on left and right sides in area of wheel hous‐
ing liner ⇒ page 377 .
– Unscrew bolts -6- from underneath.
– Fold aside wheel housing liner in front area.
– Unclip spreader clip -4- on left and right.
ic.
– Pull bumper cover -1- out of guide fasteners on left and right
of wing -arrows a-.
– Pull bumper cover -1- parallel out of catches in front end
-arrows b-.
– Detach washer fluid line hose couplings (if there are any) ⇒
Electrical system; Rep. gr. 92 ; Headlight washer system; As‐
sembly overview - headlight washer system .
– Disconnect connectors of electrical components (if present).
satelettronica
General information and work instructions for the parking aid can
be found in ⇒ Electrical system; Rep. gr. 94 ; Parking aid; As‐
sembly overview - parking aid system .
Instructions and work specifications for the Park Assist system
can be found in ⇒ Electrical system; Rep. Vgr. 94 ; Park Assist
. olkswagen AG
system (PA); Assembly overviews-waPark
gen AGAssist system (PA)
does .
olk not
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Installing edb ara
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Install in reverse orderaut of removal, observing the following: ra
c
ss
Further installation requires the assistance of a second mechanic.
ce
le
un
pt
an
d
itte
Before installing bumper cover, inspect the fastening elements,

y li
rm
ab
and renew them as necessary.

pe
ility
ot
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Panel

wit
, is n
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gaps; Body – front .

hole
spec
Specified torques
es, in part or in w
t to the co
♦ ⇒ “1.1 Assembly overview - bumper cover”, page 227
1.2.2 Removing and installing reinforcement

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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ce
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nl
pt
du
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erm
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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satelettronica
nform
mercia
at
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ion
c
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or
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for
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.
Removing
– Remove bumper cover ⇒ page 230 .
– Unclip ambient temperature sensor - G17- ⇒ Heating, air con‐
ditioning; Rep. gr. 80 ; Other control components; Removing
and installing ambient temperature sensor - G17- .
– Remove reinforcement -1- from front end.
– Detach wiring harness from reinforcement -1-.
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - bumper cover”, page 227

1.3 Repairing bumper cover

⇒ “1.3.1 Repairing bumper cover”, page 234
⇒ “1.3.2 Repair concepts of front bumper cover”, page 235
1.3.1 Repairing bumper cover
Note
If front bumper cover is damaged, determine whether plastic can

be repaired before renewing bumper.
Description under ⇒ General Information; Body Repairs, General

Body Repairs ; Plastic repair procedures .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
satelettronica
du
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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Prote AG.

1.3.2 Repair concepts of front bumper cover

Scope of delivery of front bumper cover
AG. Volkswagen AG d
The bumper cover -1- is not available as an assembly wvia
agethe
n
⇒ oes
olks not
Electronic Parts Catalogue (ETKA) . d by V gu
ara
e nte
ris
I.e., any add-on parts must be ordered separately
tho and installed eo
accordingly. s au ra
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nl
♦ The centre air intake grille -2- can be removed from the bump‐
pt
du
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er cover from the outside.
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♦ The air intake grille -3- can be removed from the bumper cover
ility
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from the outside.
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♦ The fog light trim -4- can only be removed from the inside with
hole
spec
the reinforcement -5- removed.
es, in part or in w
t to the co
♦ The reinforcement -5- can only be removed when the bumper
cover is removed ⇒ page 235 .
rrectness of i
Reworking the cut-outs for the headlight washer system on bump‐
er covers with a rough surface
l purpos
On bumper covers with a rough surface, the caps of the spray jets
satelettronica
of the headlight washer system are fitted.
nform
ercia
– On vehicles with headlight washer system, make the cut-out

m
at
and bond in the spray jet holder.
om
ion
c
in t
r
There are respective marks on the interior.

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ate
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or
Note
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Cop py
The markings for the cut-outs for the headlight washer system ht. rig
rig ht
may have incorrect dimensions. Check the markings before cut‐
py by
co Vo
by lksw
ting. Prote
cted AG.
agen
– If necessary, make a template from the damaged part.

There is an adhesive film available for the spray jet holder.
– The cut-outs for the headlight washer system can be cut
roughly using e. g. the electric cutter - V.A.G 1561 A- .
– In addition, on vehicles with ACC and bumper covers with a
rough surface the cut-out in the centre air intake grille must be
reworked.
There are marks on the inside, and a trim is clipped in from the
outside after the cut-out has been made.
Painted bumper covers
On painted bumper covers this work is not required. There will be
a replacement part for each version.
The covers for the headlight washer system are flush.
There is no trim for the opening of the sensor for adaptive cruise
control and the edges are rounded.
The parking aid sensors are located in the fog light trim and the
centre air intake grille.
Repair concept for reinforcement
Installing reinforcement using new parts:

If the bumper cover -1- and reinforcement -2- are renewed, they
are joined using securing clips -3-.
When reusing old parts, reinforcement -2- needs to be welded to
bumper cover -1- using thermal clip bonder - VAS 6872- .
Installing reinforcement using existing parts:
satelettronica
Note
♦ If the reinforcement -3- is renewed and the existing bumper

cover -1- is reused, the two components need to be welded
using the thermal clip bonder - VAS 6872- -2-.
♦ If the fog light trim needs to be removed or renewed, the re‐
spective reinforcement -3- must be removed beforehand.
♦ When separating the “spot welds” between the reinforcement n AG. Volkswagen AG do
-3- and the bumper cover -1-, make sure to retain as much olks
wage es n
ot g
material as possible to be able to re-establish the connection d by V ua
ran
at a later point. or
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– Attach clip, W-shaped - VAS 6872/5- -5- in spacer -4-
ce
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-direction of arrow b-.
pt
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– Set distance -a- precisely to 3 mm.
rm
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– Using hand set - VAS 6872/1- -2-, install clip, W-shaped - VAS
ot
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6872/5- -5- without pressure, allowing clip to melt in

h re
-arrow a-.
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spec
es, in part or in w
– When spacer -4- rests against surface, switch off hand set - t to the co
VAS 6872/1- -2-.
– Allow clip to cool down for 10 s without moving hand set - VAS
rrectness of i
6872/1- -2-.
l purpos
Note
nform
ercia
When melting in, make sure not to twist the clip, W-shaped - VAS
m
6872/5- -5-.
com
tion in
r
te o
thi
– After the cooling period has elapsed, pull off hand set - VAS
s
iva
do
6872/1- -2-, and fit next clip, W-shaped - VAS 6872/5- -5-.
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Prote AG.

AG. Volkswagen AG d
agen oes
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2 Bumper, rear ol not
byV gu
ara
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⇒ “2.1 Assembly overview - bumper cover”, pageau237
th ra
ss c
⇒ “2.2 Assembly overview - impact bar”, page 241
ce
e
nl
pt
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⇒ “2.3 Removing and installing bumper cover”, page 241
itte
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⇒ “2.4 Removing and installing impact bar”, page 243
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⇒ “2.5 Repairing bumper cover”, page 245
h re
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spec
2.1 Assembly overview - bumper cover
es, in part or in w
t to the co
⇒ “2.1.1 Assembly overview - bumper cover, Multivan ”,
page 237
rrectness of i
⇒ “2.1.2 Assembly overview - bumper cover, Transporter ”, page
239
l purpos
⇒ “2.1.3 Assembly overview - add-on parts”, page 239
nf
ercia
2.1.1 Assembly overview - bumper cover, »Multivan«
orm
m
atio
om
satelettronica
n in
or c
Note
thi
te
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Co
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cted agen
Prote AG.
2. Bumper, rear 237

1 - Middle securing strip

❑ Assembly overview - AG. Volkswagen
substructure compo‐ wage
n AG do
es n
olks
nents ⇒ page
d by 239
V ot g
ua
e ran
ris tee
2 - Bumper cover
ut
ho or
a ac
❑ Removing
ss and installing
ce
e
⇒ page 241
nl
pt
du
an
itte
3 - End piece
y li
erm
ab
ility
4 - Spreader clips
ot p
wit
, is n
h re
right
hole
spec
es, in part or in w
5 - Guide profile
t to the co
❑ Left and right
❑ Assembly overview -
rrectness of i
substructure compo‐
nents ⇒ page 239
l purpos
6 - Bolts
nf
ercia
satelettronica
o
right
rm
m
atio
m

o
n in
c
liner.
or
thi
e
❑ 2 Nm
t
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7 - Spreader clips
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❑ Left and right
Co
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8 - Spreader clips
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co
❑ Qty. 3
by lksw
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Prote AG.

2.1.2 Assembly overview - bumper cover, »Transporter«
Note
♦ Minor differences may A

be
G. encountered
Volkswagen in respect of bumper cover, depending on vehicle model.
a oes gen AG d
ksw for allocation refer to ⇒
♦ Different versions, nElectronic parts catalogue (ETKA) .
y Vol ot g
u
b ara
ed nte
oris e
th or
au ac
1- ss bumper
Rear cover
ce
e
nl
pt
du
an
itte
⇒ page 241
y li
erm
ab
ility
2 - Spreader clips
ot p
wit
, is n
❑ Qty. 3
h re
hole
spec
3 - Bolts
es, in part or in w
t to the co
right
rrectness of i
liner.
satelettronica
❑ 2 Nm
l purpos
4 - End piece
nf
ercia
❑ Left and right orm

m
atio
5 - Spreader clips
om
n in
c

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thi
right
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Prote AG.
2.1.3 Assembly overview - add-on parts
Note
♦ Minor differences may be encountered in respect of bumper

cover, depending on vehicle model.
♦ Different versions, for allocation refer to ⇒ Electronic parts
catalogue (ETKA) .
♦ Before installing substructure parts, inspect the fastening ele‐
ments, and renew them as necessary.
2. Bumper, rear 239

1 - Bumper
2 - Nut
❑ 1.5 Nm
3 - Bolts
❑ Qty. 4
❑ 20 Nm
4 - Impact bar
❑ Assembly overview
⇒ page 241 .
5 - Bolts
right
❑ 20 Nm
6 - Grommets
❑ Qty. 4
7 - Spreader rivet
❑ Qty. 4
satelettronica
8 - Right guide
9 - Middle securing strip
10 - Grommets
❑ Qty. 2
11 - Spreader rivet
❑ Qty. 4
12 - End piece
❑ Left and right
AG. Volkswagen AG d
agen
13 - Rear bumper cover Volksw
oes
not
gu
by ara
❑ Removing and installing rised
nte
⇒ page 241 ut
ho eo
ra
s a c
s
14 - Trim
ce
e
nl
pt
du
❑ Left and right

an
itte
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❑ For vehicles with wing doors

erm
ab
ility
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15 - Reflector
wit
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❑ Left and right

hole
spec
❑ Engaged in bumper cover

es, in part or in w
t to the co
16 - Clip
17 - Dampers
rrectness of i
18 - Spreader rivet
l purpos
❑ Qty. 8
19 - Grommets
nform
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❑ Qty. 8
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ate
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Prote AG.

2.2 Assembly overview - impact

agen
AG.bar
Volkswagen AG
d w oes
olks not
byV gu
ara
ed
1 - Impact bar ho
ris nte
eo
t
❑ Removing and installing au ra
c
ss
⇒ page 243
ce
e
nl
pt
du
an
2 - Bolts
itte
y li
erm
ab
❑ Qty. 4
ility
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❑ 20 Nm
wit
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nform
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at
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ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
2.3 Removing and installing bumper cover

2. Bumper, rear 241

Note
The removal and installation procedures may have to be modified slightly depending on model variants.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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un
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Removing
– Remove left and right tail light cluster ⇒ Electrical system;
rrectne
Rep. gr. 94 ; Tail lights; Removing and installing tail light clus‐
ter .
ss
– Unclip spreader clips -3- on left and right.

o
cial p
f inform
– Pull out right and left end pieces -2- upwards.

mer
atio
– Unclip spreader clips -4- on left and right.

om
n
c
i
or

thi
te
sd
va
– Unscrew spreader rivets -6- from below.

i
o
pr
cum
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fo
en

ng
t.
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ic. t. Cop py
rig
gh ht
– Lift rear bumper cover -1- on left and right simultaneously up‐ pyri by
Vo
o
by c
wards, and release it from guides -arrow a-.
lksw
cted agen
Prote AG.

– Pull rear bumper cover -1- parallel out of guides on left and
right -arrow b-.
– Disconnect connectors of electrical components (if present).
General information and work instructions for the parking aid can
be found in ⇒ Electrical system; Rep. gr. 94 ; Parking aid; As‐
sembly overview - parking aid system .
Installing
Note
♦ Before installing rear bumper cover, check securing parts and renew as necessary.
♦ For vehicles with lane change assist, the lane change assist control unit - J769- or lane change assist control
unit 2 - J770- must be recalibrated, whenever the bumper has been removed, installed or replaced.
♦ After all repair work has been completed, the lane change assist system must be calibrated
♦ General information and work instructions for the lane change assist can be found in ⇒ Electrical system;
Rep. gr. 96 ; Lane change assist .
satelettronica
– Ensure that gaps and shut lines are parallel and specified di‐
mensions are maintained ⇒ Body Repairs; Rep. gr. 00 ; Body
panel gaps/shut lines; Body - rear . Volkswa AG. gen AG
agen does
Specified torques Volksw not
gu
by ara
ed
♦ ⇒ “2.1 Assembly overview - bumper cover”,ris page 237 nte
tho eo
au ra
2.4 Removing and installing impact bar ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
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spec
es, in part or in w
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Bumper, rear 243

satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss
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nl
pt
du
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itte
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ab
ility
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wit
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spec
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t to the co
rrectness of i
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Removing
nf
ercia
orm
m
– Unscrew bolts -2- on left and right. atio

om
n in
or c
– Remove impact bar -1-.

thi
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iva
Installing
o
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f

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op py
Specified torques t. C rig
gh ht
pyri by
♦ ⇒ “2.2 Assembly overview - impact bar”, page 241
co Vo
by lksw
cted agen
Prote AG.

2.5 Repairing bumper cover

⇒ “2.5.1 Assembly overview - parking aid retainer, bumper cover”,
page 245
⇒ “2.5.2 Repairing bumper cover”, page 245
⇒ “2.5.3 Installing brackets for parking aid system”, page 246
2.5.1 Assembly overview - parking aid retainer, bumper cover
1 - Rear bumper cover

❑ General information and
work instructions for the
parking aid can be found
in ⇒ Electrical system;
Rep. gr. 94 ; Parking
aid; Assembly overview
- parking aid system .
⇒ page 241
2 - Rear centre parking aid wage
satelettronica
es n
olks ot g
sender db
y V ua
ran
se
❑ Rear centre left parking thori tee
or
aid sender - G204- ss
au ac
❑ Rear centre right park‐
ce
le
un
pt
ing aid sender - G205-
an
d
itte
y li
rm
ab
3 - Rear left parking aid sender
pe
ility
- G203-
ot
wit
, is n
h re
4 - Sensor bracket
hole
spec
❑ Installing brackets for
es, in part or in w
parking aid system
t to the co
⇒ page 246
5 - Rear right parking aid send‐ rrectness of i
er - G206-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
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t.
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Cop py
ht. rig
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2.5.2 Repairing bumper cover
by lksw
cted agen
Prote AG.
Note
If rear bumper cover is damaged, determine whether plastic can

be repaired before renewing bumper.
Description under: ⇒ General Information; Body Repairs, General

Body Repairs ; Plastic repair procedures
2. Bumper, rear 245

2.5.3 Installing brackets for parking aid sys‐

tem
♦ Installation tool for PDC bracket - VAS 6614-
lkswage es n
o ot g
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tho
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un
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ab
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, is n
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hole
spec
Materials
es, in part or in w
t to the co
♦ Cleaning solution ⇒ Electronic Parts Cata‐
satelettronica
logue (ETKA)
rrectness of i
l purpos
Note
♦ Observe manufacturer's instructions enclosed in the packag‐

nform
ercia
ing.
m
a
com
♦ Observe minimum drying time ⇒ page 249 .

tion in
r
te o
thi
Installing brackets
s
iva
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Note
Co
Cop py
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The brackets are installed after the bumper cover has been pain‐
p by
co Vo
by lksw
ted. Prote
cted AG.
agen

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut
h
ra Transporter 2016 ➤
s c
s General body repairs, exterior - Edition 10.2019
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
satelettronica
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The 4 markings for brackets -1- can be found on the inside of the
bumper cover.
– If there are no markings, the centre point -2- must be deter‐
mined.
– The holes must be drilled from the inside to the outside with
the drill in the tool kit -3-.
2. Bumper, rear 247

satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Set hole punch in position with bolt head -1-, washer -2- and
es, in part or in w
thrust bearing -3- from inside bumper cover -5-.

t to the co
– Screw on punch -4-, not quite as far as bumper cover.

– Press punch -4- against bumper cover.
rrectness of i
– Tighten hole punch -1-.

l purpos
nf
ercia
Note
orm
m
atio
m
Do not permit the punch -4- to turn on the paint of the bumper cover.
o
n in
or c
thi
te
– Pull punch -4- through the material of bumper cover -5-

sd
iva
o
r
-arrows- by turning the bolt head -1-.

rp
cu
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– Remove hole punch and make next holes.

t.
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t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Transporter ara 2016 ➤
nte
ris
ut
ho General body repairs, exterior - Edition 10.2019 eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Thoroughly clean bonding surfaces on bumper cover -4-.

– Push bracket -2- onto centring pin -1-.
– Pull backing off double-sided adhesive tape on bracket.
Note
Do not touch the adhesive surface of the bonded punched component once the protective backing has been
removed. Otherwise the bonding strength will be impaired.
– Insert centring pin -1- into hole until the bracket is touching the
bumper cover -4-.
– Press bracket forcefully against bonding surface -3-.
– Removing centring pin and repeat the procedure for all brack‐
ets.
– Further work can carried out on bumper cover only after min‐
imum curing period ⇒ page 249 .
Minimum curing period
Do not carry out any further work on the bumper cover or brackets
until the minimum curing period of 2 hours has expired.
2. Bumper, rear 249

The minimum curing period must be observed so that the adhe‐

sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is. Do not
move it.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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un
pt
an
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itte
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ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

64 – Glazing
1 Repair notes
agen
AG. Volkswagen AG d
o
w es n
olks o
⇒ “1.1 Minimumd bcuring
yV periods for bonded windows”,
t gu page 251
ar
e an
ris tee
⇒ “1.2 Window
ut
ho repair”, page 251 or
a ac
ss
⇒ “1.3 Installation instructions for bonded windows”, page 252
ce
le
un
pt
an
⇒ “1.4 Preparing old undamaged windows for fitting”, page 253
d
itte
y li
rm
ab
⇒ “1.5 Preparing new windows for installing”, page 254
pe
ility
ot
wit
⇒ “1.6 Preparing body flange for fitting”, page 255
, is n
h re
hole
⇒ “1.7 Cleaning off excess adhesive”, page 256
spec
es, in part or in w
t to the co
1.1 Minimum curing periods for bonded win‐
dows
rrectness of i
There are special requirements for renewing bonded windows.
l purpos
satelettronica
One of these standards is, for example, that a freshly bonded
windscreen must comply with the safety requirements, even in an
accident, following the minimum prescribed curing period.
nform
ercia
The vehicle is safe to use only after the minimum curing period
m
a
com
ti
has elapsed.
on in
r
te o
thi
2-component adhesive
s
iva
do
r
The minimum curing time for the 2-component adhesive is 2 hours

rp
cum
fo
for all windows.

en
ng
t.
yi Co
op
The operational safety of the vehicle is restored completely after
C py
t. rig
gh
2 hours.
ht
pyri by
Vo
co lksw
by
1-component adhesive
cted agen
Prote AG.
The minimum curing time for the 1-component adhesive is 6 hours

for all windows.
The vehicle is definitely safe to operate again after 6 hours if the
1-component adhesive is used.
For 2-component adhesive and 1-component adhesive
Irrespective of which adhesive is used, the vehicle can be moved
again half an hour after the window has been installed.
Minimum curing period is the time from bonding the window until
vehicle may be used (operational safety). During this time, the
vehicle must be standing on a level surface at room temperature
(at least 15°C).
1.2 Window repair
Note
♦ Before renewing windscreen, explore possibilities of repairing

damage to glass.
♦ Damaged windscreens can be repaired with the window repair
kit - VAS 6092- .
♦ This damage must remain within a certain size or position.
♦ Each window repair kit comes with a set of instructions.
1. Repair notes 251

♦ Window repair kit - VAS 6092-
lkswage es n
o ot g
byV ua
d ran
ir se
1.3 Installation instructions for bonded win‐ utho tee
or
dows
a ac
ss
ce
le
un
pt
⇒ “1.3.1 Fitting instructions”, page 252
an
d
itte
y li
rm
ab
⇒ “1.3.2 Materials”, page 252
pe
ility
ot
wit
1.3.1 Fitting instructions
, is n
h re
satelettronica
hole
spec
– Apply adhesive sealing material -1- in continuous bead, hold‐
es, in part or in w
ing applicator at right angle to window -2-.
t to the co
Note
rrectness of i
l purpos
Window must be installed within 10 minutes, or adhesive proper‐

ties of glass adhesive will be impaired.
nform
ercia
♦ Adhere to the specified dimensions for the adhesive beads.

m
a
com
ti
♦ Using 2 suction lifters - V.A.G 1344- , install glass pane in win‐

on in
dow aperture, align to centre and press in onto spacing lip.

r
te o
thi
s
iva
♦ Replace stickers (e.g. for airbag) if there were any.

do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3.2 Materials
Note
For part numbers of the materials, refer to the ⇒ Electronic parts

catalogue (ETKA) .
♦ 2-pack window adhesive 1) 2) 3) 6)
♦ 1-pack window adhesive 1) 2) 4) 5) 6)
♦ Activator 1) 6)
♦ Glass and paint primer 1) 6)
♦ Cleaning solution 1) 6)
♦ Primer applicator 1) 6)
252 Rep. gr.64 - Glazing

♦ Adhesive remover 1) 6)
AG. Volkswagen AG d
swagen oes
k not
Vol
♦ Cutting cord 357 ed by853 999 6) 7 gu
ara
ris nte
ho eo
♦ ut
Wire reels aVAS 7 ra
c
6452/1 s
ce
e
nl
pt
du
an
♦ Cutting cord 7
itte
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erm
6888/1
ab
ility
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, is n
1)Observe manufacturer's instructions enclosed in the packag‐
h re
hole
ing.
spec
es, in part or in w
2)
t to the co
Observe minimum curing period ⇒ page 251 .
3) Use double cartridge gun - VAS 5237- to apply these materials.
rrectness of i
4)Heat according to manufacturer’s instructions using cartridge
heater - V.A.G 1939- .
l purpos
5)Small cartridge, 180 ml, for sealing and/or when a 400 ml dou‐
nform
ercia
ble cartridge alone is not sufficient.

m
6)
at
satelettronica
For part numbers of the materials, refer to the ⇒ Electronic
om
io
n
c
in t
or
his
e
7
t
The cutting cords stated above can be used alternatively to the

a
do
riv
cutting wires, and vice versa. They are designated for single use.
p
cum
for
en
ng
1.4 Preparing old undamaged windows for

t.
yi Co
Cop py
fitting
t. rig
gh ht
pyri by
Vo
o
by c lksw
Cutting back adhesive bead cted agen
Prote AG.
♦ If an undamaged window is being re-used, cut back the resid‐

ual adhesive sealant to 1 to 2 mm shortly before bonding it
back in.
♦ Do not damage primer and ceramic coating when doing this.
♦ Keep bonding surface free of dirt and grease.
♦ Do not treat bonding surface with activator, glass/paint primer
or cleaning solution immediately after cutting back.
♦ The remaining material is required as a base for better adhe‐
sion of the new adhesive sealing material to be applied.
WARNING
Exception: if bonding is performed later than one day after cut‐

ting back adhesive bead, the remaining residual material must
be activated with activator .
Apply activator evenly in one stroke using applicator .
The activator must not come in contact with paint, or the paint‐
work will be damaged.
Drying time approx. 10 minutes.
• Exception: if bonding is performed later than one day after

cutting back adhesive bead, the remaining residual material
must be activated with activator .
– Apply activator evenly in one stroke using applicator .
Allow to air dry for approx. 10 minutes.
1. Repair notes 253

1.5 Preparing new windows for installing
Note
♦ The application area for the adhesive bead is not precoated

or primed.
♦ The relevant area is a ceramic coating.
♦ No windows are precoated.
♦ The sealing lip is included with a new windscreen.
– Using cleaning solution , clean edge of window all round to a

width of 20 mm.
– Then rub edge of window dry using a lint-free cloth.
WARNING
The ceramic coating on the window is not glass or paint primer!

The ceramic coating must be primed before application of ad‐
satelettronica
hesive sealing compound! Use only glass/paint primer
D 009 200 02!
– Using applicator -2-, apply glass/paint primer -3- evenly in one

pass onto ceramic coating -1-.
– Apply activator evenly in one stroke using applicator
gen AG
. Volks.wagen AG
d wa oes
olks not
♦ Allow to air dry for approx. 10 minutes.
db
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ara
e nte
ris
utho eo
ra
a c
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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agen
AG. Volkswagen AG d
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General
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body repairs, exterior - Edition 10.2019
d
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1.6 Preparing body flange for fitting
ss au ra
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♦ Cut back residual adhesive sealant to 1 … 2 mm shortly before
nl
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bonding window back in.
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ility
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♦ Keep bonding surface free of dirt and grease.
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♦ Do not treat bonding surface with activator, glass/paint primer
t to the co
or cleaning solution immediately after cutting back.
♦ The remaining material is required as a base for better adhe‐
sion of the new adhesive sealing material to be applied.
rrectness of i
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WARNING
nf
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Exception: if bonding is performed later than one day after cut‐
orm
ting back adhesive bead, the remaining residual material must
m
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be activated with activator .

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Apply activator evenly in one stroke using applicator .
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– Cut back remaining material on body flange with U-shaped
Prote AG.
blade - V.A.G 1561/3- , but do not remove completely.

– Apply activator evenly in one stroke using applicator .
♦ If the window flange has been repaired or partially renewed,
the area concerned must be cleaned and primed again after
painting.
– Clean metal flange all around using cleaning solution .
– Then rub edge of window dry using a lint-free cloth.
– Apply glass/paint primer evenly in one pass onto paintwork
structure using applicator .
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 glass adhesive before bonding the window.
1. Repair notes 255

– If laser weld seam -3- on metal flange -4- is not covered by

existing adhesive bead -1-, coat laser weld seam -3- with
glass/paint primer -3-. Then fill laser weld seam with glass ad‐
hesive -1-.
Touching up paint damage
The paint structure must be restored after damage to the paint‐
work according to specifications in the ⇒ “Paint workshop man‐
ual” .
1.7 Cleaning off excess adhesive

– Use adhesive remover as cleaning agent. Safety precautions
must be observe for all work procedures.
Note
satelettronica
♦ When cleaning the vehicle interior, do not press freshly instal‐
led window outwards.
♦ Otherwise, the window will be detached.
– First, clean the painted surface roughly with a dry cloth. Re‐
move residue using adhesive remover . AG. Volkswagen AG d
agen oes
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– Cleaning plastic trim: Allow adhesive sealant to cureis(approx.
ed
b ua
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1 hour) and then peel off. thor tee
or
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2 Windscreen
⇒ “2.1 Assembly overview - windscreen”, page 257
⇒ “2.2 Removing and installing windscreen”, page 261
2.1 Assembly overview - windscreen

⇒ “2.1.1 Assembly overview - windscreen”, page 257
⇒ “2.1.2 Windscreen spacings”, page 257
2.1.1 Assembly overview - windscreen
1 - Windscreen
⇒ page 261
2 - Sealing lip
3 - PUR adhesive sealant
❑ Cross section of bead:
satelettronica
width = 6.5 mm, height = agen
AG. Volkswagen AG d
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glass and window thor eo
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❑ Minimum curing period
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⇒ page 251 .
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❑ To set to a uniform gap.
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Allocation ⇒ Electronic parts
t to the co
catalogue (ETKA)
6 - Windscreen seal rrectness of i

❑ Is part of windscreen.
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7 - Plenum chamber cover

❑ Must be removed from
nform
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windscreen seal by
hand only.
m
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io

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⇒ page 18
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2.1.2 Windscreen spacings

Dimensions for adhesive bead and glass/paint primer at upper
edge of windscreen ⇒ page 258
Dimensions for adhesive bead and glass/paint primer at lower
Dimensions for adhesive bead and glass/paint primer at side
2. Windscreen 257
Dimensions for adhesive bead and glass/paint primer at upper

edge of windscreen
1 - Windscreen
2 - Glass and paint primer
❑ Distance from sealing
lip to edge of applied ad‐
hesive bead.
4 - Roof frame
5 - Sealing lip
7 - Moulded headliner
AG. Volkswagen AG d
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ate
Dimensions for adhesive bead and glass/paint primer at lower

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lkswage es n
d byV
o ot g
ua Transporter 2016 ➤
ran
ho
ir se General body
tee repairs, exterior - Edition 10.2019
ut or
a ac
ss
1 - Windscreen
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3 - Cowl panel
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5 - Windscreen seal
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rrectness of i
hesive bead.
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Dimensions for adhesive bead and glass/paint primer at side

edge of windscreen
2. Windscreen 259
1 - Windscreen
4 - Sealing lip
5 - A-pillar
hesive bead.
satelettronica
AG. Volkswagen AG d
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2.2 Removing and installing windscreen

equipment required
AG. Volkswagen AG d
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♦ Removal kit for flush bonded windows - VAS 6452-

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♦ Cutting tool - V.A.G 1351- by c lksw
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♦ Windscreen removal kit - V.A.G 1755-
♦ Double cartridge gun - VAS 5237-
♦ Hand-cartridge gun - V.A.G 1628-
2. Windscreen 261
AG. Volkswagen AG d
agen oes
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byV gu
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nl
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du
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Prote AG.
♦ Electric cutter - V.A.G 1561A-

♦ Universal cutter - V.A.G 1561/11-
♦ Blades, 15 and 25 mm - V.A.G 1561/7+8-
♦ Scraper (45 mm) - V.A.G 1561/20-
♦ Windscreen removal kit - VAS 861 001A-
♦ Cartridge heater - V.A.G 1939A-

Removing
– Removing plenum chamber cover ⇒ page 18 .
– If fitted, disconnect electrical connector and additional earth
wire for windscreen heater in area of plenum chamber.
– Remove A-pillar trims ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, interior; Removing and installing A-pillar trim .
– Remove interior mirror ⇒ General body repairs, interior; Rep.
gr. 68 ; Interior mirror; Removing and installing interior mirror .
Note
♦ To prevent damage to the sealing lip on the windscreen, loos‐

en the sealing lip from the window flange in the upper area of
the windscreen using a plastic wedge.
♦ Then, spray the window flange with cleaning solution (as sub‐
stitute for lubricant).
– Slide protective backing - V.A.G 1474/8- -1- between front

windscreen and dash panel.
satelettronica
– Pull cutting cord -3- through adhesive sealing material into in‐
side of vehicle using awl - V.A.G 1474 A- -2-.
– Secure inside end of cutting cord against falling out using Pull
toggle - V.A.G 1351/1- -3-.
. Volkswagen AG
gen AG does
– Insert cutting cord -2- into window flange usingVotube
lksw -1-.
a
not
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– If gap is too small, guide cutting cord onooutside
ris
e and push un‐ nte
eo
der sealing lip with a plastic wedge. auth ra
ss c
– Place cutting cord around window.
ce
e
nl
pt
du
an
– Ensure that cutting cord lies under windscreen in corners.

itte
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t to the co
rrectness of i
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at
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c
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do
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t.
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263
c by lksw
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Prote AG. 2. Windscreen
– Secure other end of cord to reel device - V.A.G 1654 - .

– Start reeling device - V.A.G 1654 - in “position I”.
– Turn reel device - V.A.G 1654 - accordingly and cut wind‐
screen free.
– Use wedge - V.A.G 1474/5- to press cutting cord against wind‐
screen while cutting in order to gain clearance at window
flange and dash panel.
Installing
Preparing old undamaged window for glazing ⇒ page 253 .
Preparing new window for glazing ⇒ page 254 .
Preparing body flange for glazing ⇒ page 255 .
Installation instructions ⇒ page 252
Minimum curing period ⇒ page 251
Windscreen adhesive dimensions ⇒ page 257
satelettronica
AG. Volkswagen AG d
agen oes
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byV gu
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Prote AG.

3 Side window
⇒ “3.1 Assembly overview - side windows”, page 265
⇒ “3.2 Removing and installing rear side window”, page 268
3.1 Assembly overview - side windows

⇒ “3.1.1 Assembly overview - side windows, rear”, page 265
⇒ “3.1.2 Assembly overview - centre side window”, page 266
⇒ “3.1.3 Assembly overview - side window, double cab”,
page 267
3.1.1 Assembly overview - side windows, rear
Note
satelettronica
1 - Side window
⇒ page 268
2 - Ceramic layer
3 - Sealing lip
AG. Volkswagen AG d
4 - PUR adhesive sealant agen oes
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❑ Cross section of bead: ised b ara
nte
width = 6.5 mm, height = ut
hor eo
10 mm (including resid‐ ss a ra
c
ual material on window
ce
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un
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glass and window
an
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flange)
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5 - Dimension = 8 mm
hole
spec
❑ Distance from edge of

es, in part or in w
t to the co
window to centre of ap‐

plied adhesive bead.
rrectness of i
❑ Gap from edge of win‐

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dow to body panel

nform
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Prote AG.
3. Side window 265

3.1.2 Assembly overview - centre side window
1 - Rear side window

⇒ page 268
2 - Centre side window
⇒ page 268
3 - Sealing lip n AG. Volkswagen AG do
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4 - PUR adhesive sealant byV
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❑ Cross section of bead: ir se tee
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width = 6.5 mm, height = aut or
ac
10 mm (including resid‐ ss
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⇒ page 251 .
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spec
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❑ Distance from edge of
t to the co
plied adhesive bead.
rrectness of i
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dow to body panel
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7 - Depth stop
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3.1.3 Assembly overview - side window, double cab
Note
Only the left wing door side is shown. The right wing door side is similar.
1 - Side window
⇒ page 268
❑ Cross section of bead: lkswage es n
o ot g
width = 6.5 mm, height = d byV ua
ran
10 mm (including resid‐ ir se tee
ho
ual material on window aut or
ac
glass and window ss
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flange)
un
pt
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itte
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⇒ page 251 .
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3 - Wing door
wit
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4 - Spacer rib
spec
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❑ Part of window.
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3. Side window 267

3.2 Removing and installing rear side win‐

dow
⇒ “3.2.1 Removing undamaged side window in sliding door”, page
268
⇒ “3.2.2 Removing broken side window in sliding door”,
page 269
⇒ “3.2.3 Installing side window in sliding door”, page 269
⇒ “3.2.4 Removing undamaged side window”, page 269 AG. Volkswagen
n AG do
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⇒ “3.2.5 Removing broken side window”, page 271 ot g
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au ac
⇒ “3.2.7 Removing undamaged doublesscab side window”,
ce
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page 271
un
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⇒ “3.2.8 Removing broken double cab side window”, page 273
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⇒ “3.2.9 Installing double cab side window”, page 273
ot
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3.2.1 Removing undamaged side window in sliding door
h re
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spec
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es, in part or in w
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♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit - V.A.G 1755- AG. Volkswagen AG d
agen oes
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♦ Double cartridge gun - VAS 5237- by
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♦ Hand-cartridge gun - V.A.G 1628- ut
hor eo
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– Remove lower sliding door trim ⇒ General body repairs, inte‐ s
ce
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nl
pt
du
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rear door trim .
itte
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ility
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Ensure that cutting cord lies under windscreen in corners.
h re
hole
– Pull end of cutting cord through adhesive sealant into inside
spec
es, in part or in w
of vehicle using awl - V.A.G 1474 A- .
t to the co
rrectness of i
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satelettronica
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– Pull outer end of cord into vehicle.

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– Counterhold with pull handle - V.A.G 1351/1- .

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– Secure other end of cord to reel device - V.A.G 1654 - . pyri
gh by
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– Cut side window free by moving reel device to required posi‐
lksw
cted agen
Prote
tion.
AG.
– Use wedge - V.A.G 1474/5- to press cutting cord against win‐

dow while cutting in order to have clearance at window flange.
Have a second mechanic hold the side window.
3.2.2 Removing broken side window in sliding

door
Removing a broken side window is performed in the same man‐
ner as removing a broken rear window ⇒ page 301 .
3.2.3 Installing side window in sliding door

3.2.4 Removing undamaged side window
3. Side window 269

General body repairs, exterior - Edition G. Volkswagen AG d
gen A10.2019
swa k
oes
not
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d by ara
Special tools and workshop ris
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equipment required utho eo
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Prote AG.

– Remove upper C-pillar trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, interior; Removing and installing C-pillar
trim .
– Remove upper D-pillar trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, interior; Removing and installing D-pillar
trim .
– Detach moulded headliner at top, and lower it ⇒ General body
repairs, interior; Rep. gr. 70 ; Roof trims; Removing and in‐
stalling moulded headliner .
– Detach rear side panel trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, interior; Removing and installing side trim .
– Remove connections for window aerial.

Ensure that cutting cord lies under windscreen in corners.

– Pull end of cutting cord through adhesive sealant into inside
of vehicle using awl - V.A.G 1474 A- .
– Pull outer end of cord into vehicle.

– Counterhold with pull handle - V.A.G 1351/1- .
– Secure other end of cord to reel device - V.A.G 1654 - .
– Cut side window free by moving reel device - V.A.G 1654 - to
required position.
satelettronica
– Use wedge - V.A.G 1474/5- to press cutting cord against win‐
Have a second mechanic hold the side window.
3.2.5 Removing broken side window . Volkswagen AG

gen AG does
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Removing a broken side window is performed in the same man‐ yV
olk not
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ner as removing a broken rear window ⇒ page 301 . rised b ara
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3.2.7 Removing undamaged double cab side window
rrectness of i
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tion in
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te o
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Prote AG.
3. Side window 271


equipment required
satelettronica
AG. Volkswagen AG d
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ng
t.
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1755- and use handle -1- to force it through adhesive bead.
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Look for a place where the gap is the largest. Protect the paint‐ yri
p by
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work at this place from damage.
c by lksw
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Prote AG.
– Unscrew handle -1- and thread end of cutting cord through eye
of needle.
– Pull in trimming needle with end of cutting cord.
– Use pliers and gloves.

– Secure inside end of cutting cord against falling out using Pull
toggle - V.A.G 1351/1- -1-.
– Place cutting cord around side window.
– Guide other end of cord into vehicle as well.
• Ensure that cutting cord lies under side window in corners.
• Have a second mechanic hold the side window.
– Secure other end of cutting cord to reel device - V.A.G 1654
A- .
– Cut side window free by moving reel device - V.A.G 1654 A-
to required position.
– Use wedge - V.A.G 1474/5- to press cutting cord against side
window while cutting in order to have clearance at window
flange.
3.2.8 Removing broken double cab side win‐

dow
Removing a broken double cab side window is performed in the
satelettronica
same manner as removing a broken rear window ⇒ page 301 .
3.2.9 Installing double cab side window AG. Volkswagen AG d

agen oes
lksw not
Preparing old undamaged window for glazing ⇒ page 253 .by V o gu
ara
ed
is nte
Preparing new window for glazing ⇒ page 254 . ut
hor eo
a ra
s c
Preparing body flange for glazing ⇒ page 255 . s
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3. Side window 273

4 Sliding window
⇒ “4.1 Assembly overview - sliding window”, page 274
⇒ “4.2 Removing sliding window for sliding door”, page 279
⇒ “4.3 Removing broken sliding window for sliding door”,
page 285
⇒ “4.4 Installing sliding window for sliding door”, page 285
⇒ “4.5 Checking and observing new sliding window prior to in‐
stallation”, page 286
⇒ “4.6 Removing and installing movable section of sliding win‐
dow”, page 287
⇒ “4.7 Removing undamaged sliding window for side panel”, page
289
⇒ “4.8 Removing broken sliding window for side panel”,
page 292
⇒ “4.9 Installing sliding window for side panel”, page 293
4.1 Assembly overview - sliding window
satelettronica
⇒ “4.1.1 Assembly overview - sliding window for sliding door”,
page 274
⇒ “4.1.2 Assembly overview - movable section of sliding window”,
page 276
⇒ “4.1.3 Assembly overview - movable section of sliding window,
California”, page 277
⇒ “4.1.4 Assembly overview - sliding window fornside
AG. Vpanel”,
olkswagepage
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278 olkswage oes
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4.1.1 Assembly overview - sliding window for sliding door tho
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Note
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♦ The right side is shown. The left side is similar.

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♦ The upper -2- and lower -3- guide rail covers are only installed in commercial vehicles.
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swage es n
1 - Complete sliding window byV
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❑ Removing ⇒ page 279 hor is tee
ut or
❑ Installing ⇒ page 285 ss a ac
ce
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2 - Cover for upper guide rail
nl
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❑ Unclip cover from upper
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3 - Cover for lower guide rail
hole
spec
❑ Unclip cover from lower
es, in part or in w
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t to the co
4 - Spacer rib
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❑ Part of window
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❑ 3 each at top and bottom

❑ 1 each at front and rear
nf
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om
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width = 6.5 mm, height =
or c
satelettronica
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10 mm (including resid‐
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glass and window
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⇒ page 251 .
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❑ Gap between edge of
window to body panel
dow to centre of applied
adhesive bead
4. Sliding window 275

4.1.2 Assembly overview - movable section of sliding window
1 - Movable section of sliding

window
⇒ page 287
2 - Button
3 - Bottom pin
4 - Top pin
5 - Centring pin
6 - Locking peg
satelettronica
AG. Volkswagen AG d
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AG. Volkswagen AG d
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olksw not
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4.1.3 Assembly overview - movable section of sliding window, California
ise nte
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1 - Movable section of sliding
pt
an
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window
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⇒ page 279
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2 - Button
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spec
3 - Centring pin
t to the co
❑ Lower right
4 - Locking peg
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❑ Lower left
5 - Locking peg
ss o
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❑ Upper left
f inform
mer
6 - Centring pin
atio
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❑ Upper right
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4.1.4 Assembly overview - sliding window for side panel
Note
1 - Complete sliding window

❑ Installing ⇒ page 293
2 - Cover for upper guide rail
❑ Unclip cover from upper
guide rail in
3 - Cover for lower guide rail
❑ Unclip cover from lower n AG. Volkswagen AG do
guide rail in lkswage es n
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4 - Spacer rib auth or
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❑ Part of window.
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❑ 3 each at top and bottom
du
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❑ 1 each at front and rear
erm
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glass and window
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⇒ page 251 .
l purpos
6 - Dimension a = 3 mm nf
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or
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m
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lkswage es n
uaTransporter 2016 ➤
o ot g
byV
d ran
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ir se General body repairs, exterior t-eeEdition 10.2019
ut or
a ac
ss
4.2 Removing sliding window for sliding
ce
le
un
pt
door
an
d
itte
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rm
ab
⇒ “4.2.1 Removing undamaged sliding window for sliding door”,
pe
ility
ot
page 279
wit
, is n
h re
⇒ “4.2.2 Removing and installing movable section of sliding win‐
hole
spec
dow, California”, page 281
es, in part or in w
t to the co
4.2.1 Removing undamaged sliding window for sliding door
rrectness of i
l purpos
equipment required
nform
mercia
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tion in
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te o
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n
t.
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Cop py
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General body repairs, exterior - Edition 10.2019en AG. Volkswagen AG
ag does
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tion in
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satelettronica
s
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t.
yi Co
Cop py
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Prote AG.

♦ Blades, 15 and 25 mm - V.A.G 1561/7+8-
♦ Scraper (45 mm) - V.A.G 1561/20-

Note
Sliding windows equipped with aewater

n AG. Vodrain
lkswagsystem
en AG cannot be
removed without damage. olkswag does
not
yV gu
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– Remove lowerutsliding
ho
r
door trim ⇒ General body repairs, inte‐eo
rior; Rep. gr.ss a70 ; Rear door trims; Removing and installing r ac
rear door trim .
ce
e
nl
pt
du
an
– From outside, cut through rear section of adhesive bead -1- in
itte
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window aperture using electric cutter - V.A.G 1561A- -2- and
erm
ab
ility
universal blade - V.A.G 1561/11- (with adjustable stop roller).
ot p
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– Close sliding door.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
ercia
– Guide cutting cord -1- towards inside on left and right sides
using a trimming needle from the windscreen removal kit -
m
at
om
V.A.G 1755- .
ion
c
in t
or
• Look for a place where the gap is the largest. Protect the
his
ate
paintwork at this place from damage. do

priv
cum
or
– Place cutting cord -1- around adhesive bead.

f
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ng
t.
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• Ensure that cutting cord -1- lies under window in corners. C py
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– Cut through adhesive bead -1- in front area using pulling han‐
p by
co Vo
by lksw
dle - V.A.G 1351/1- -2-. Prote
cted AG.
agen
– Guide cutting cord -1- to outside on left and right sides using
a trimming needle.
Begin along lower adhesive bead.
Ensure that cutting cord -1- lies under window in corners.
– Cut through adhesive bead with pulling handle - V.A.G
1351/1- .
Have a second mechanic hold the sliding window when separat‐
ing the upper adhesive bead.
– Place cutting cord -1- around adhesive bead and cut sliding
window free using pulling handle - V.A.G 1351/1- -2-.
4.2.2 Removing and installing movable sec‐

tion of sliding window, California

♦ Removal wedge - 3409-
satelettronica
AG. Volkswagen AG d
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olksw not
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es, in part or in w
t to the co
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nform
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tion in
r
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iva
do
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t.
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Cop py
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by
Removing Prote
cted AG.
agen
– Remove roof side member trim ⇒ General body repairs, Cal‐

ifornia; Rep. gr. 75 ; Trims, interior; Removing and installing
roof side member trim .
– Cover glass surfaces on cross section.
– Push driver's seat forwards as far as it will go.
– Remove roller blind of left side window.

– Move sliding window -1- to middle position.

– Make sure that button -2- for sliding window -1- does not en‐
gage in this position; it must remain in open position.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ris nte
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aut ra
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nl
pt
du
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satelettronica
wit
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es, in part or in w
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nf
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atio
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
– Carefully press the upper plastic frame upwards using a

wedge - 3409- .
– Prise upper pin -2- of sliding window -1- out of guide.

satelettronica
lkswage es n
o ot g
byV ua
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ility
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es, in part or in w
t to the co
wedge - 3409- .
– Prise upper pin -2- on left of sliding window -1- out of guide.
rrectness of i
– Fold down upper part of sliding window -1- and pull out of
guide.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
en
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t.
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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satelettronica
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♦ Ensure that the centring pins -2- and -3- swing outwards.
co Vo
by lksw
cted agen
Prote AG.
♦ Hold button in open position to ensure locking peg remains down.
4.3 Removing broken sliding window for

sliding door
Removing a broken sliding window is performed in the same
manner as removing a broken rear window ⇒ page 301 .
4.4 Installing sliding window for sliding door

Checking and observing new sliding window prior to installation
⇒ page 286 .


4.5 Checking and observing new sliding window prior to installation

G. Volkswage A n AG d
agen oes
Check prior to installation: ksw not
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ility
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wit
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es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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by c lksw
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Prote AG.
On the sliding window -1-, there must be 10 spacers -2- (3 each

at top and bottom and 2 each at front and rear).
The adhesive bead -3- must be applied next to the spacers -2-.
To be observed on installation

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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nl
pt
du
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Alignment with rear side window: gap 4 mm, slight projection up

erm
ab
to 1 mm.
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Install sliding window -1- free of stress, i.e.

h re
hole
spec
• Push on sliding window -1- evenly until it rests against spacers

es, in part or in w
(Qty. 10).
t to the co
• Do not push on sliding window -1- again especially in the areas

around the front and rear corners.
rrectness of i
• In upper area, fix sliding window -1- in place with fabric adhe‐
sive tape, but do not press on forcefully.
l purpos
• Secure sliding window -1- with a wedge -2- (3 mm) to prevent

nform
slipping while the polyurethane adhesive sealant cures.

mercia
• The window adjuster can be used as a wedge -2-. Adjust

at
om
io
wedge -2- using workshop equipment.

n
c
in t
or
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• When inserting sliding window -1-, do not secure suction lifter

ate
do
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- V.A.G 1344- on movable section of sliding window -1-.

p
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for
4.6 Removing and installing movable sec‐

en
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t.
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op
tion of sliding window
C py
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Prote AG.

Removing
Vehicles with roller blinds
– Remove roller blind ⇒ General body repairs, California; Rep.
gr. 77 ; Blackout roller blinds; Removing and installing left side
window roller blind .
– Half open sliding window -1-.
satelettronica
– Make sure that button a-2-
genfor
AG.sliding window
Volkswagen AG
doe-1- does not en‐
ksw s no
gage in this position;
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ility
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spec
t to the co

wedge - 3409- .
rrectne
– Prise upper pin -1- of sliding window -2- out of guide.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Then prise upper pin -2- of sliding window -1- out of guide.
Caution
Protect roller frame against scratching using suitable adhesive

tape.
– Tilt sliding window -1- forwards and inwards with a slight ro‐
tational motion.
Installing AG. Volkswagen AG d
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ss c
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nl
satelettronica
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Make sure that the centring pins -2- swing outwards.
l purpos
♦ Hold button in open position to ensure locking peg -3- remains

down.
nf
ercia
orm
m
atio
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n in
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4.7 Removing undamaged sliding window for side panel

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equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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Prote AG.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
te o
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iva
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r

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t.
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Cop py
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♦ Blades, 15 and 25 mm - V.A.G 1561/7+8- opyri
gh by
Vo
ht
c
♦ Scraper (45 mm) - V.A.G 1561/20-
by lksw
cted agen
Prote AG.

– Remove upper C-pillar trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Trims, interior; Removing and installing C-pillar
trim .
– Remove upper D-pillar trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, interior; Removing and installing D-pillar
trim .
– Detach moulded headliner at top, and lower it ⇒ General body
repairs, interior; Rep. gr. 70 ; Roof trims; Removing and in‐
stalling moulded headliner .
– Detach rear side panel trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, interior; Removing and installing side trim .
Protect the paint on the B-pillar against damage with adhesive
tape from the outside.
– From inside, cut through front section of adhesive bead in win‐
dow aperture -1- using electric cutter - V.A.G 1561/A- -2- and
universal blade - V.A.G 1561/11- .
AG. Volkswagen AG d
agen oes
olksw not
satelettronica
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
– Take trimming needle from windscreen removal kit - V.A.G
itte
y li
erm
1755- , and use handle to force it through adhesive bead.
ab
ility
ot p
– Guide cutting cord -1- towards inside using trimming needle.
wit
, is n
h re
hole
spec
es, in part or in w
• Ensure that cutting cord -1- lies under window in corners.
t to the co
– Cut through adhesive bead using pull handle - V.A.G 1351/1-
-2-.
rrectness of i
l purpos
nf
ercia
– Take trimming needle from windscreen removal kit - V.A.G

rm
m
atio
1755- , and use handle to force it through adhesive bead.

om
n in
c
Begin along lower adhesive bead.

or
thi
te
sd
a
– Guide cutting cord -1- at top and bottom towards outside using
iv
o
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cu
trimming needle.
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f
en
ng
t.
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Co
Cop py
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– Cut free sliding window using pull handle - V.A.G 1351/1-
rig ht
py by
o Vo
-2-. by c lksw
cted agen
Prote AG.
• Ensure that cutting cord -1- lies under window in corners.
Have a second mechanic hold the sliding window when separat‐
ing the upper adhesive bead.
4.8 Removing broken sliding window for

side panel
Removing a broken sliding window for the side panel is performed
in the same manner as removing a broken rear window
⇒ page 301 .

4.9 Installing sliding window for side panel

Checking and observing new sliding window prior to installation
⇒ page 286 .
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5 Rear windscreen
⇒ “5.1 Assembly overview - rear window”, page 294
⇒ “5.2 Removing and installing rear window”, page 298
5.1 Assembly overview - rear window

⇒ “5.1.1 Assembly overview - rear window, rear”, page 294
⇒ “5.1.2 Assembly overview - rear window, double cab and drop‐
side”, page 295
⇒ “5.1.3 Assembly overview – rear window, wing door”,
page 296
⇒ “5.1.4 Assembly overview - rear window, sliding window for
partition panel”, page 297
5.1.1 Assembly overview - rear window, rear agen

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⇒ page 298
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8 - Trim

5.1.2 Assembly overview - rear window, double cab and dropside
1 - Rear windscreen
⇒ page 298
glass and window
flange)
⇒ page 251 .
3 - Rear wall
4 - Spacer rib
❑ Part of window.
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5. Rear windscreen 295

5.1.3 Assembly overview – rear window, wing door

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⇒ page 298 ut
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⇒ page 251 .
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5 - Left rear wing door
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5.1.4 Assembly overview - rear window, sliding window for partition panel
1 - Partition panel
2 - Complete sliding window
⇒ page 304
3 - Button
4 - Rear window, rigid
⇒ page 304
5 - Seal n AG. Volkswagen AG do
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⇒ “5.2.2 Removing
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⇒ “5.2.7 Installing rear window”, page 304
⇒ “5.2.8 Removing and installing sliding window and rear window
for partition”, page 304
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5.2.1 Removing undamaged rear window,
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double cab and dropside
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m
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in the same manner as removing an undamaged rear window
com
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⇒ page 301 .
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same manner as removing a broken rear window ⇒ page 298 . opyri
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5.2.3 Removing undamaged rear window
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equipment required
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♦ Blades, 15 and 25 mm - V.A.G 1561/7+8-

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– Pull off connectors for heated rear window, and push connec‐
tor tabs against rear window.
– Remove wiper arm ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Removing and installing wiper arm .
– Take trimming needle -1- from windscreen removal kit - V.A.G
1755- and use handle -2- to force it through adhesive bead.
Look for a place where the gap is the largest. Protect the paint‐
work at this place from damage.
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– Use the pull handle - V.A.G 1351/1- -1- to secure end of cutting
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5.2.4 Removing broken rear window


General body repairs, exterior - Edition 10.2019 agen
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– Remove connections to window heater unit.

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hesive tape.
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– Cut through adhesive sealant (with pieces of glass) in window
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aperture using electric cutter - V.A.G 1561 A- -1- and blade -
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5.2.5 Removing undamaged wing door window

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Note
Removal is described for the undamaged left wing door window

only. Removal of the undamaged right wing door window is sim‐
ilar.
– Remove wiper arm ⇒ Electrical system; Rep. gr. 92 ; Rear

window wiper system; Removing and installing wiper arm .
– Pull off connection for heated rear window and press connect‐
ing tab onto window.

– Use awl - V.A.G 1474/2- -2- to poke through adhesive sealant

outwards.
– Pull cutting cord -1- through adhesive sealant into vehicle in‐
terior using awl - V.A.G 1474/2- .
– On inside, prevent end of cutting cord -2- from being pulled out
by attaching it to pull handle - V.A.G 1351/1- -1-.
– Guide cutting cord -2- around wing door window.
• Ensure that cutting cord lies under wing door window in cor‐
ners.
satelettronica
• Have a second mechanic hold the wing door window.
– Secure other end of cutting cord to reel device - V.A.G 1654

A- .
– Cut wing door window free by moving reel device - V.A.G 1654
A- to required position.
– Use wedge - V.A.G 1474/5- to press cutting cord against wing
door window while cutting in order to have clearance at win‐
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5.2.6 Removing damaged wing door window

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Removing damaged wing door window is performed in same

, is n
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manner as removing broken rear window ⇒ page 301 .

hole
spec
5.2.7 Installing rear window

es, in part or in w
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5.2.8 Removing and installing sliding window and rear window for partition
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Removal and installation are described only for rear window -3- equipped with window rubber. Removal and
Cop py
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installation of complete sliding window -2- is analogous.
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Removing thi
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– Release rear window rubber -3- from inside out over window
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flange using removal wedge - 3409- .

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– Press rear window -3- with window rubber out of partition from
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– Insert filler profile -4- in window rubber.
– Spray window rubber with soapy water.
– Insert thread inserting tool - V.A.G 1818- around window rub‐
ber.
Further installation requires the assistance of a second mechanic.
– Insert rear window -3- with window rubber in window aperture.
– Pull out thread inserting tool - V.A.G 1818- all the way around
from inside and thereby pull sealing lip over door flange.

6 Door windows
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⇒ “6.1 Removing and
ed installing front door window”, page 306
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⇒ “6.2 Adjusting
au front door window”, page 307
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6.1 Removing and installing front door win‐
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Removing
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gr. 70 ; Front door trims; Removing and installing front door
yi Co
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trim .
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– Lever out caps -1-. cop Vo
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– Lower door window until clamping bolts -2- for door window
become accessible.
Note
If the electric window regulator is faulty, the window regulator mo‐

tor can be unbolted allowing you to push the window down.
– Loosen bolts -2- (do not remove) and press clamping brackets
apart.
– Remove inner window slot seal.
– Lift rear of door window and swing door window towards front
in -direction of arrow- out of door.
Installing
Specified torques
Door window 8 Nm

6.2 Adjusting front door window

– Lower door window -1- until clamping bolts -2- for door window
are accessible.
– Loosen clamping bolts -2- (do not unscrew completely).
satelettronica
– Slide door window -1- without additional force into clamping
jaws.
– Align door window to rear window channel -arrow-.
– Tighten clamping bolts -2-.
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6. Door windows 307

66 – Exterior equipment
1 Radiator grille and front trim
⇒ “1.1 Assembly overview - radiator grille”, page 308
⇒ “1.2 Removing and installing radiator grille”, page 308
1.1 Assembly overview - radiator grille
1 - Radiator grille
⇒ page 308
2 - Spreader clip
❑ Qty. 3
3 - Clip
❑ For battery cover
satelettronica
4 - Badge
⇒ page 393
5 - Lettering
❑ BlueMotion
❑ Engaged in radiator
grille
❑ Can only be unclipped
with radiator grille re‐
moved
6 - Lettering
❑ 4 Motion AG. Volkswagen AG d
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1.2 Removing and installing radiator grille

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Removing
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308
Prote AG.
Rep. gr.66 - Exterior equipment
– Release all locking hooks of radiator grille -1-.

– Press locking hooks out of openings -arrows- of bumper cover
-2- and radiator grille -1-.
– Pull radiator grille -1- in -direction of arrow- parallel out of
bumper cover -2-.
Installing
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– Insert radiator grille -1- parallel in -direction of arrow- into
es, in part or in w
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bumper cover -2-.
– With slight pressure, clip radiator grille -1- into bumper cover
-2- -arrows-.
rrectness of i
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1. Radiator grille and front trim 309

2 Spoiler
⇒ “2.1 Removing and installing spoiler”, page 310
2.1 Removing and installing spoiler

⇒ “2.1.1 Repair notes”, page 310
⇒ “2.1.2 Removing and installing front spoiler”, page 311
⇒ “2.1.3 Removing and installing rear spoiler”, page 312
2.1.1 Repair notes
Note
♦ For part numbers of the materials, refer to the ⇒ Electronic

♦ The spoiler is bonded at the factory with adhesive.
♦ The spoiler is primed by the supplier.
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must be approximately the same (18 °C and max. 30 °C).

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Add-on parts must be installed within 10 minutes, as bonding
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t to the co
in the spoiler and using the vehicle.
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er has been bonded for at least 4 hours.
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Preparing body component for bonding
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– Cut back adhesive to about 1 mm without damaging paint‐
cial p
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work.
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The residual material serves as a primer for application of the new atio
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– The cut surfaces do not require additional cleaning.
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If bonding is performed later than one day after cutting back ad‐
hesive bead, remaining residual material must be activated with
activator.
Apply activator evenly in one stroke using applicator.
The activator must not come in contact with paint, or the paintwork
will be damaged.
– New spoiler may be attached immediately to bonding surface
at specified positions.
310 Rep. gr.66 - Exterior equipment

If the bumper cover has been repaired or partially renewed, the

area concerned must be cleaned and primed again after painting.
2.1.2 Removing and installing front spoiler

♦ Hot-air blower - V.A.G 1416-
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2. Spoiler 311
– Unclip spreader rivets -3- (qty. 10) from front spoiler -1-.
– Apply gentle heat from hot air blower - V.A.G 1416- to upper
area of front spoiler -1-. gen AG
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2.1.3 Removing and installing rear spoiler


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– Unclip spreader rivets -3- (qty. 6) from rear spoiler -1-.
area of rear spoiler -1-. rrectness of i
– Carefully apply removal wedge - 3409- -2- between rear spoil‐
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– Apply force gradually to pull rear spoiler -1- off bumper cover.
nform
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Installing
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2. Spoiler 313
– Apply adhesive to bonding surfaces -3- on inner side of rear

spoiler -1-.
– With aid of a second mechanic, fit rear spoiler -1- to bumper
cover so that it is straight.
– Align rear spoiler -1- with bumper cover.
– Insert spreader rivets -2- (qty. 6).
– Press on front spoiler -1- in area of bonding surface.
satelettronica
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3 Mouldings, trims, extensions

⇒ “3.1 Assembly overview - B-pillar trim”, page 315
⇒ “3.2 Assembly overview - guide rail”, page 317
⇒ “3.3 Assembly overview - heat shield”, page 318
⇒ “3.4 Removing and installing trim strip”, page 319
⇒ “3.5 Removing and installing side member trim”, page 326
⇒ “3.6 Removing and installing roller guide trim”, page 328
⇒ “3.7 Removing and installing wing cover”, page 330
⇒ “3.8 Removing and installing guide rail”, page 330
⇒ “3.9 Renewing roof strip”, page 333
⇒ “3.10 Removing and installing underbody heat shield”,
page 333
3.1 Assembly overview - B-pillar trim
satelettronica
Note
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3. Mouldings, trims, extensions 315

1 - B-pillar trim
2 - Blind rivet nut
❑ Qty. 2
3 - Bolts
❑ Qty. 2
❑ 4 Nm
4 - Clip
❑ Qty. 2
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3.2 Assembly overview - guide rail
Note
1 - Guide rail
⇒ page 330
2 - Bolts
❑ Qty. 7 AG. Volkswagen AG d
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5 - Speed nuts
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❑ Inserted into roof from
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3.3 Assembly overview - heat shield
Note
Different versions; for allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
1 - Heat shield
❑ Plenum chamber bulk‐
head
❑ May be bent to allow for
installation of the cool‐
ant hose. Must be bent
back to original position
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2 - Clamping washer d byV
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4 - Heat shield
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⇒ page 333
es, in part or in w
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5 - Clamping washers
❑ Qty. 3
rrectness of i
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❑ Qty. 3
7 - Heat shield
nform
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❑ For front tunnel, con‐

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⇒ page 333 thi

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❑ Tunnel, centre Prote AG.

10 - Heat shield
❑ Rear tunnel, connecting pipe
11 - Bolt
❑ 3.5 Nm
❑ Qty. 3
13 - Heat shield
❑ Rear silencer

14 - Bolts
❑ Qty. 2
❑ 3.5 Nm
❑ Qty. 3
16 - Bolts
❑ Qty. 2
❑ 23 Nm
17 - Bolts
❑ Qty. 3
❑ 23 Nm
❑ Qty. 3
❑ Qty. 2
20 - Clamping washer
satelettronica
❑ Pre-assembled
21 - Bolts
❑ Qty. 7
❑ 8 Nm
22 - Heat shield AG. Volkswagen AG d
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❑ Removing and installing ⇒ page 333 rised
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23 - Heat shield ss
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24 - Bolts
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3.4 Removing and installing trim strip

rrectness of i
⇒ “3.4.1 Removing and installing trim strip”, page 319

l purpos
⇒ “3.4.2 Removing and installing chrome strips”, page 322

⇒ “3.4.3 Dimensions for trim strip”, page 324
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⇒ “3.4.4 Dimensions, chrome strips”, page 326

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3.4.1 Removing and installing trim strip

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♦ Adhesive strip remover - VAS 6349-
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Removing
Note
♦ Depending on model and vehicle equipment, trim strips with chrome finish may be installed.
♦ Only the left and rear sides are shown. The right side is analogous.
♦ Protective strips cannot be removed without being damaged.
– Warm protective strip with hot air blower - V.A.G 1416- before
removing, and pull off.
– Remove residual material of double-sided adhesive tape using
adhesive strip remover - VAS 6349- .
Installing
– Clean body in assembly area with adhesive remover.
– Preheat body and protective strips to approx. 18-35℃.
• Bonding surfaces must be dry, free of dust, grease, dirt and
other media.
• Remove backing only immediately before installation.

– Pull off protective foil on protective strips.

– The protective strips are aligned at the same height and bon‐
ded in position.
– Deviations in height between individual protective strips must
be no more than 1 mm.
Dimensions ⇒ page 324 .
3.4.2 Removing and installing chrome strips

AG. Volkswagen AG d
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♦ Adhesive strip remover - VAS 6349- pt

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satelettronica
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Removing
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Note
t to the co
♦ Only the left and rear sides are shown. The right side is analogous.
rrectness of i
♦ Protective strips cannot be removed without being damaged.

l purpos
– Heat protective strip with a hot air blower - V.A.G 1416- and
then remove protective strip.
nform
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– Remove residual material of double-sided adhesive tape using

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adhesive strip remover - VAS 6349- .

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other media.
AG.
• Remove backing only immediately before installation.

– Pull protective films of chrome strips.

– The chrome strips are aligned at the same height and should
be stuck on evenly across the whole length.
Note
Deviations in height between individual chrome strips must be no

more than 1 mm.
Dimensions ⇒ page 324 .
3.4.3 Dimensions for trim strip
Note
❑ Lower edge of protec‐ lkswage es n
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tive strip toslower edge
satelettronica
d b ua
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2 - Dimensionss b = 325 mm c
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❑ Lower edge of protec‐

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of end piece.
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3.4.4 Dimensions, chrome strips
❑ Lower edge of chrome
strip to lower edge of
door.
strip to lower edge of B-
pillar trim.
strip to side panel
swage line or lower
edge of door.
4 - Dimension d = 1-2 mm
❑ Lower edge of chrome AG. Volkswagen AG d
strip to lower edge of lksw
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3.5 Removing and installing side member

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Repair notes
Note
♦ For part numbers of the materials, refer to the ⇒ Electronic

♦ The side member trim is bonded at the factory with adhesive.
The temperature of the room, of the work bay and of the vehicle
must be approximately the same (18 °C and max. 30 °C).en AG. V
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Side member trim must be installed within 10 minutes,
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The minimum drying time is the period in time between bonding
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Preparing body component for bonding
es, in part or in w
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– Cut back adhesive to about 1 mm without damaging paint‐
work.
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rrectness of i
adhesive.
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– Immediately before installation, thoroughly clean side member

trim of dirt, grease, wax and other impurities.
nform
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– Always use a clean, lint-free cloth for cleaning.

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– The cut surfaces do not require additional cleaning.
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If bonding is performed later than one day after cutting back ad‐ cum
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hesive bead, remaining residual material must be activated with

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Apply activator evenly in one stroke using applicator.
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The activator must not come in contact with paint, or the paintwork
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Prote AG.
will be damaged.
– New side member trim may be attached immediately to bond‐
ing surface at specified positions.
If the side member has been repaired or partially renewed, the
area concerned must be cleaned and primed again after painting.
Removing
Note
♦ The side member trim cannot be removed without damage.

♦ The side member trim at front and rear is removed and instal‐
led together with the decorative strip.
♦ When removing the side member trim, make sure not to dam‐
age the paintwork of the side member.

– Remove bolt -2- from below.

– Unscrew bolt -3- from front.
– Working from below, unclip spreader rivets -4- (qty. 2 on each
bracket) from side member trim -1-.
area of side member trim -1-.
– Apply force gradually to pull side member trim -1- off side
member.
Installing
– Protective foil for side member is attached ⇒ page 362 .
• Decorative strip is attached to side member trim at front and
at rear.
– Apply adhesive to bonding surfaces -5- on inner side of side
satelettronica
member trim -1-.
– With aid of a 2nd mechanic, fit side member trim -1- to side
member so that it is straight.
– Align side member trim -1- properly on side member. agen
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– Press on side member trim -1- in area of bonding surface.
aut
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– Screw in bolts -2- and -4-.
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Specified torque
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♦ ⇒ “10.1 Assembly overview – special add-on parts”,
ility
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page 395
wit
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3.6 Removing and installing roller guide trim
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Note
♦ The removal and installation sequence is only for the right sliding door. The removal and installation of the
left sliding door is similar.
satelettronica
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Removing
atio
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– Remove tail light cluster ⇒ Electrical system; Rep. gr. 94 ;

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Tail lights; Removing and installing tail light cluster in rear lid .
te
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– Undo and remove bolts -1- at front and rear from cover -2-.
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– Pull cover -2- in direction of -arrow- out of side panel until all
retaining clips (Qty. 7) -3- are released from their fasteners.

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Transporterth 2016 ➤
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Generalssbody repairs, exterior - Edition 10.2019
a ac
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Installing
an
d
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Note
spec
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Before installing cover -2-, check securing parts -3- and renew if
necessary.
rrectne
• Then, check operation of sliding door.
Specified torques
ss o
cial p
f
inform
mer
Roller guide trim 2 Nm
atio
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n
3.7 Removing and installing wing cover
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Removal and installation sequence is only for the left wing trian‐
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Removing
– Lever wing triangular cover -1- off A-pillar with a plastic wedge.
Installing
– Press wing triangular cover -1- into opening.
Note
Before installing wing triangular cover -1-, check securing parts

and renew as necessary.
3.8 Removing and installing guide rail


AG. Volkswagen AG d
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– Remove roof luggage rack.

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– Unscrew bolts -2- and -3- from guide rail -1-.
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♦ Bolting sequence is only for left guide rail. The right side is analogous.
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The bolts must be tightened in following sequence:

– First tighten bolt -1- then tighten bolt -2-, the remaining bolts
can be tightened in any order.

Specified torques
♦ ⇒ “3.2 Assembly overview - guide rail”, page 317
3.9 Renewing roof strip

– Remove guide rail ⇒ page 330 .
– Roof strip -1- can be bonded in with 1-pack glass adhesive.
– Vertical position of roof strip -1- must be aligned with roof and
side panel.
WARNING
Roof strip panel must be installed within 10 minutes otherwise

adhesive properties of adhesive will be impaired.
satelettronica
3.10 Removing and installing underbody
heat shield
⇒ “3.10.1 Removing and installing underbody heat shield, front
tunnel, converter”, page 333
⇒ “3.10.2 Removing and installing underbody heat shield, front
exhaust pipe tunnel”, page 334
⇒ “3.10.3 Removing and installingagunderbody
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tunnel, connecting pipe”,
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page 335 or
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⇒ “3.10.5 Removing and installing underbody heat shield, centre
ce
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nl
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Removing
Vehicles with all-wheel drive
– Remove front and rear propshaft ⇒ Propshaft and rear final
drive; Rep. gr. 39 ; Propshaft; Removing and installing prop‐
shaft .
– Remove tunnel heat shield for front exhaust pipe
⇒ page 334 .
– Loosen lock washers -3-.
– Remove heat shield -1-.
Installing
Specified torques
♦ ⇒ “3.3 Assembly overview - heat shield”, page 318
satelettronica
heat shield, front exhaust pipe tunnel
Removing
Note
Slight discrepancies may need to be allowed for depending on

the type of engine.

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334
Prote AG.
Rep. gr.66 - Exterior equipment
Removing
Note

the type of engine.
satelettronica
– Remove rear silencer ⇒ Rep. gr. 26 ; Exhaust pipes/silencers;
Removing and installing rear silencer . AG. Volkswagen A
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Removing
Note

the type of engine.

Removing and installing rear silencer .
– Remove heat shield -1-. olkswage es n
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Install in reverse order of removal, observing
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Removing
AG.
Note

the type of engine.

Removing and installing rear silencer .
– Remove rear brake cable ⇒ Brake system; Rep. gr. 46 ;
Parking brake; Removing and installing rear brake cable .

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General body repairs, oexterior
ra - Edition 10.2019
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4 Noise insulation agen AG. Volkswagen AG do

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⇒ page 338
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4.2 Removing and installing noise insulation


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4. Noise insulation 339

Transporter 2016 ➤ agen
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5 Underbody cladding
This manual may have lost its validity due to modifications by ABT
e-Line, or may have to be supplemented by additional repair in‐
structions from ABT e-Line.
Please refer to the Electronic Service Information System (El‐
saPro), section “Superstructures and modifications” for relevant
repair manuals regarding modifications by ABT e-Line.
You can also obtain them from ABT e-Line.
⇒ “5.1 Assembly overview - underbody cladding”, page 341

⇒ “5.2 Removing and installing underbody cladding”, page 357
5.1 Assembly overview - underbody cladding

satelettronica
olkswagen AG
ag en AG. V
This manual may have lost its validity due toVomodifications
lksw by ABT does
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e-Line, or may have to be supplemented ed b by additional repair in‐
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structions from ABT e-Line. ho
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5. Underbody cladding 341

⇒ “5.1.1 Assembly overview - underbody cladding, PanAmerica‐

na”, page 342
⇒ “5.1.2 Assembly overview - air ducting”, page 343
⇒ “5.1.3 Assembly overview - front left outer underbody cover”,
page 344
⇒ “5.1.4 Assembly overview - front left underbody cover”,
page 345
⇒ “5.1.5 Assembly overview - front right underbody cover”,
page 346
⇒ “5.1.6 Assembly overview - rear axle cladding, middle”,
page 347
⇒ “5.1.7 Assembly overview - rear axle cladding, left”,
page 349
⇒ “5.1.8 Assembly overview - rear axle cladding, right”,
page 350
⇒ “5.1.9 Assembly overview - cladding behind spare wheel”, page
351
⇒ “5.1.10 Assembly overview - cladding before spare wheel”,
satelettronica
page 352
⇒ “5.1.11 Assembly overview - rear left underbody cover”,
page 353
⇒ “5.1.12 Assembly overview - rear middle underbody cover”,
page 354
⇒ “5.1.13 Assembly overview - rear left underbody cover”,
page 355
⇒ “5.1.14 Assembly overview - rear right underbody cover”, page
356
5.1.1 Assembly overview - underbody

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This manual may have lost its validity
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1 - Skid plate
❑ Engine and gearbox
⇒ page 357
2 - Bolts
❑ Qty. 6
❑ 30 Nm
3 - Bracket
❑ For rear axle differential
❑ Qty. 2
⇒ page 357 AG. Volkswagen AG d
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⇒ page 357
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7 - Bolts
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❑ 15 Nm
5.1.2 Assembly overview - air ducting


Note

♦ The removal and installation procedures and the fastening elements may be slightly different depending on
model.
♦ If required, detach or remove adjacent trim pieces.
1 - Air duct
2 - Bolts
❑ Qty. 2
❑ 3.8 Nm
❑ Qty. 2
satelettronica
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5.1.3 Assembly overview - front left outer underbody cover

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This manual may have lost its validity due to modifications by ABT by c lksw
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e-Line, or may have to be supplemented by additional repair in‐ Prote AG.

Note

model.
1 - Front left outer underbody

cover
❑ -Arrow- indicates direc‐
tion of normal travel
2 - Bolt
❑ Qty. 6
❑ 3.8 Nm
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5.1.4 Assembly overview - front left underbody cover

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2 - Bolts
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5.1.5 Assembly overview - front right underbody cover


Note

model.
1 - Front right underbody cover

2 - Bolts
❑ Qty. 6
satelettronica
❑ 3.8 Nm
❑ Qty. 2
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5.1.6 Assembly overview - rear axle cladding, middle

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5.1.7 Assembly overview - rear axle cladding, left

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5.1.8 Assembly overview - rear axle cladding, right

Note

model.
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1 - Rear axle cladding, right

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5.1.9 Assembly overview - cladding behind spare wheel

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5.1.10 Assembly overview - cladding before spare wheel

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5.1.11 Assembly overview - rear left underbody cover

AG. Volkswagen AG d
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refer to ⇒ Electronic parts catalogue (ETKA) eo .
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ce
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un
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1 - Rear left underbody cover
hole
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2 - Bolts
❑ Qty. 3
rrectness of i
❑ 3.8 Nm
l purpos
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5.1.12 Assembly overview - rear middle underbody cover

Note

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♦ The removal and installation procedures
Vol
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and the fastening elements
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not may be slightly different depending on
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♦ If required, detach oraremove
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5.1.13 Assembly overview - rear left underbody cover

Note

model.
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AG. Volkswagen AG d
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1 - Rear left underbody cover olksw not
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❑ -Arrow- indicates direc‐ orise nte
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2 - Bolt
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❑ Qty. 6
d
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5.1.14 Assembly overview - rear right underbody cover

Note AG. Volkswagen AG d

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model. ss c
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❑ 3.8 Nm rrectness o
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5.2 Removing and installing underbody cladding

. Volkswagen AG
a gen AG does
This manual may have lost its validity due to modifications
Vol
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gu
e-Line, or may have to be supplemented byedadditional repair in‐
by ara
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structions from ABT e-Line. tho
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Please refer to the Electronic Servicess Information System (El‐ c
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⇒ “5.2.1 Removing and installing underbody cladding, engine and
gearbox”, page 357
⇒ “5.2.2 Removing and installing underbody cladding, rear axle
rrectness of i
differential”, page 358
l purpos
⇒ “5.2.3 Removing and installing bracket for rear axle differential”,

page 359
satelettronica
nf
ercia
o
⇒ “5.2.4 Removing and installing underbody cladding, centre si‐
rm
m
lencer”, page 360
atio
om
n in
c

or
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cladding, engine and gearbox

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Removing
– Detach underbody cladding for engine and gearbox -1- down‐
wards.
Installing
Specified torques
♦ ⇒ “5.1.1 Assembly overview - underbody cladding, PanAmer‐
icana”, page 342
satelettronica
cladding, rear axle differential
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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un
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spec

t to the co
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s

s o

cial p
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mer
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n
c
i
or
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pr
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fo
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d byV gu
e
horis General body
nte repairs,
eo exterior - Edition 10.2019
aut ra
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Removing
ce
e
nl
pt
du
an
– Unscrew bolts -2- from underneath.
itte
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ab
– Unscrew bolts -3- from front.
ility
ot p
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– Detach underbody cladding for rear axle differential -1- down‐
, is n
h re
wards.
hole
spec
Installing
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos
icana”, page 342
nf
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m
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or c
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5.2.3 Removing and installing bracket for rear
f
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t.
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axle differential Cop py
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rig ht
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Special tools and workshop equipment required co Vo
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♦ Engine and gearbox jack - VAS 6931-


Removing
– Remove underbody cladding for rear axle differential
⇒ page 358 .
– Support final drive with engine and gearbox jack - VAS 6931-
-3-.
– Unscrew bolts -2- from bracket -1- on left and right.
– Remove bracket -1- on left and right.
Installing
– Fit bracket -1- on left and right.
Note
Start bolts -2- (do not tighten).
satelettronica
– Install underbody cladding for rear axle differential
⇒ page 358 .
AG. Volkswagen AG d
agen oes
Specified torques Volksw not
gu
by ara
d
♦ ⇒ “5.1.1 Assembly overview - underbody
horise cladding, PanAmer‐ nte
eo
icana”, page 342 aut ra
c
ss
ce
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un
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an
d
itte
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cladding, centre silencer

erm
ab
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spec
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cial p
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mer
atio
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c
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p
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op
e-Line, or may have to be supplemented by additional repair in‐ C py
t. rig
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ht
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Please refer to the Electronic Service Information System (El‐ cted agen
Prote AG.

Removing
– Unscrew bolts -2-. AG. Volkswagen AG d
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– Unscrew nuts by -3-.
Vo gu
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– Detachuthunderbody
or
cladding for centre silencer -1- downwards.
eo
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Installing s
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nl
pt
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itte
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Specified torques
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icana”, page 342
hole
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6 Trim film and protective film

⇒ “6.1 Renewing decorative film and protective film”, page 362
6.1 Renewing decorative film and protective

film
⇒ “6.1.1 Renewing protective films”, page 362
⇒ “6.1.2 Renewing decorative film”, page 363
6.1.1 Renewing protective films

satelettronica
AG. Volkswagen AG d
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Bonded protective film cannot bessremoved without damage.
a c
ce
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If a protective film is installed for the first time on a new vehicle or

un
pt
an
d
a newly painted surface, follow the procedure described in the ⇒

itte
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rm
Paintwork manual ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mould‐ ab

pe
ility
ings and film .
ot
wit
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If protective film is removed and re-fitted, use only adhesive re‐

h re
hole
mover to remove the adhesive residue.

spec
es, in part or in w
Ensure that the adhesive surfaces are free of dust and grease.
t to the co
Apply protective film immediately after cleaning.

rrectness of i
Do not remove protective film until immediately before installation.

l purpos
Working temperature is approx. 21 °C.

Procedure
nform
ercia
• Side member extension has been removed ⇒ page 326 .

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Prote AG.

– Heat protective film on side member -1- using hot air blower -
V.A.G 1416- before removing.
– Carefully pull protective film -1- off side member.
Other equipment
♦ Soapy solution; proposed mixture ratio: 3 g washing-up liquid
to 100 ml water
♦ Felt squeegee
♦ Spray bottle
♦ Lint-free cloths
♦ Washing-up liquid
– Spray a thin film of soapy water onto side member using a
spray bottle.
– Pull backing off protective film for side member -1-.
– Position protective film -1- on side member.
– Force out excess water from centre towards left or towards
right using felt squeegee.
satelettronica
– Press on protective film -1- again using felt squeegee to force
out air bubbles.
AG . Volkswagen AG
– Clean protective film -1- withksawdry
agencloth. does
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Vol gu
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6.1.2 Renewing decorative film ris nte
tho eo
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Note
o
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c
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or
n thi
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♦ Decorative film cannot be removed without damage.

t
sd
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♦ Affix protective film using water and soap.

fo
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t.
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♦ Exact mixing ratio is 1 ml washing-up liquid to 1 l water. The Cop py
mixture should be mixed well.
t. rig
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co
♦ Bonding surfaces must be free of dust and grease.
by lksw
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– Spray a thin film of soapy water onto exterior panel using a

spray bottle.
– Pull off protective foil on adhesive side of decorative film.
– Apply and align decorative film. Push water out from under film
using plastic blade wrapped in soft paper tissue. Tissue is re‐
quired to prevent hard edge of plastic blade from scratching
film.
6. Trim film and protective film 363

Fitting instructions
Before removing decorative film, heat it with a hot air blower -
V.A.G 1416- .
If the decorative film is installed for the first time on a new vehicle
or on newly painted surfaces, follow the procedure in ⇒ Repair
manual "Paint"; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mouldings
and film .
When removing and reinstalling decorative film, adhesive remov‐
er is the only aid that is allowed to ebe
n Aused
G. Volkto
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agen AG the adhesive
residue. olks
wag does
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Apply decorative films
ris immediately after cleaning.
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ss a surface protective backing immediately before r ac
installation.
ce
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nl
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t to the co
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nform
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c
in t
or
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ate
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7 Exterior mirror
⇒ “7.1 Assembly overview - exterior mirror”, page 365
⇒ “7.3 Removing and installing mirror glass”, page 369
⇒ “7.4 Removing and installing mirror trim”, page 371
⇒ “7.5 Removing and installing mirror cover”, page 373
⇒ “7.2 Removing and installing exterior mirror”, page 367
7.1 Assembly overview - exterior mirror

⇒ “7.1.1 Assembly overview - exterior mirror”, page 365
⇒ “7.1.2 Assembly overview - exterior mirror, double cab and
dropside”, page 366
7.1.1 Assembly overview - exterior mirror
Note
satelettronica
1 - Mirror mounting
⇒ page 367
2 - Dampers AG. Volkswagen AG d
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3 - Bolts ised b ara
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❑ 6 Nm s
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4 - Warning lamps for lane

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change assist
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⇒ Electrical system;
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Rep. gr. 96 ; Lane

hole
change assist; Remov‐

spec
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ing and installing lane

t to the co
change assist warning

lamp in exterior mirror
5 - Electrical connectors
rrectness of i
6 - Mirror glass
l purpos

⇒ page 369
nform
ercia
7 - Mirror trim
m
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com
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n in
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⇒ page 371
te o
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8 - Bolt
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❑ 2 Nm
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9 - Bolts C py
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10 - Mirror cover
❑ Bottom
7. Exterior mirror 365

⇒ page 373
AG. Volkswagen AG d
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Overview - TV system
ss
13 - Aerial module
ce
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nl
pt
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❑ Removing and installing ⇒ Communication; Rep. gr. 91 ; Aerial system; Overview - aerial system
itte
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14 - Mirror cover
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7.1.2 Assembly overview - exterior mirror, double cab and dropside
rrectness of i
l purpos
Note
nform
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satelettronica
m
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ion
c
1 - Mirror mounting
in t
or
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2 - Dampers
do
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❑ Qty. 3 . Cop py
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4 - Mirror glass cted agen
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5 - Housing frame
❑ Engaged in mirror hous‐
ing
Note
The housing frame cannot be re‐

moved without being damaged.
6 - Adjuster unit
7 - Mirror housing
8 - Bolt
❑ Qty. 2
❑ 2 Nm
9 - Cover
10 - Aerial module
❑ Integrated in mirror
mounting -1-
⇒ Communication;
Rep. gr. 91 ; Aerial sys‐
tem; Overview - aerial
system

7.2 Removing and installing exterior mirror

⇒ “7.2.1 Removing and installing exterior mirror”, page 367
⇒ “7.2.2 Removing and installing double cab and dropside exte‐
rior mirror”, page 369
7.2.1 Removing and installing exterior mirror

lkswage es n
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Note
itte
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Removal and installation are described only for the left side. Removal and installation of the right side is similar.
ot p
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satelettronica
AG. Volkswagen AG d
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Removing
h re
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spec


t to the co
trim .
– Disconnect earth wire and connectors -3- from subframe.
rrectnes
Note
s o
cial p
f in
Depending on the equipment level, other connectors and earth wires may be present and need to be discon‐
form
mer
nected prior to the removal.

atio
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– Remove exterior mirror -1- from door.

i
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Specified torques
♦ ⇒ “7.1 Assembly overview - exterior mirror”, page 365

7.2.2 Removing and installing double cab and

dropside exterior mirror
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Removing
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satelettronica
trim .
nform
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– If fitted, disconnect connectors for heated exterior mirror.

m
at
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– Remove screws -2- and take exterior mirror -1- off door.
ion
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his
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Specified torques
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♦ ⇒ “7.1.2 Assembly overview - exterior mirror, double cab and
lksw
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AG.
7.3 Removing and installing mirror glass

♦ Removal lever - 80 - 200-
Note

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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Removing
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un
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– Protect housing edges to prevent damage to paintwork with,

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WARNING
h re
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When doing this repair work, always wear safety goggles and
es, in part or in w
t to the co
leather gloves!
rrectness of i
– Press bottom of mirror glass -1- in -direction of arrow- into

mirror housing.
l purpos
– Using removal lever - 80 - 200- , press mirror glass -1- in di‐

rection of arrow -B- off adjustment unit.
nform
ercia
– Swing mirror glass -1- towards side.

m
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tion in
– Disconnect connectors -2- at rear of mirror glass -1-.

r
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Installing
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– Connect connectors -2- for exterior mirror heating to mirror Cop py
glass -1-.
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Prote AG.

– Push mirror glass -1- centrally onto adjustment unit in housing.

wage
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Note utho eo
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The mirror glass -1- can be heard to engage in catch.
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– Then check function.
rm
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7.4 Removing and installing mirror trim
wit
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♦ Torque wrench - V.A.G 1783- es, in part or in w
t to the co
rrectness of i
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nform
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satelettronica
on in
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Cop py
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♦ Removal and installation are described only for the left side. Removal and installation of the right side is Prote AG.
similar.
♦ If there is any damage on or inside the exterior mirror, the mirror housing and lower trim must be renewed.
The mirror housing must be painted depending on the equipment.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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Prote
Removing
AG.
– Remove mirror glass ⇒ page 369 .

– Remove mirror cover at top ⇒ page 373 .
– Remove mirror cover at bottom ⇒ page 373 .
– Push tab -3- slightly towards front -arrow A-.
– Press together retaining hook -3- -arrow B-.
– Push mirror trim -1- towards front off mirror mounting -2-.
Installing
– Push mirror trim -1- onto mirror mounting.
Note
The mirror trim -1- must be heard to engage.

7.5 Removing and installing mirror cover

⇒ “7.5.1 Removing and installing mirror cover at top”, page 373
⇒ “7.5.2 Removing and installing mirror cover at bottom”,
page 374
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Removing
– Remove mirror glass ⇒ page 369 .
– If fitted, unclip lane change assist warning lamp -2- from ex‐
terior mirror housing -1- ⇒ Electrical system; Rep. gr. 96 ;

Lane change assist; Removing and installing lane change as‐

sist warning lamp in exterior mirror .
– Release retaining hooks -2-.
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– Then check function.
Specified torques
♦ ⇒ “7.1 Assembly overview - exterior mirror”, page 365

8 Wheel housing liner

⇒ “8.1 Assembly overview - front wheel housing liner”,
page 376
⇒ “8.2 Assembly overview - rear wheel housing liner”,
page 377
⇒ “8.3 Removing and installing front wheel housing liner”,
page 377
⇒ “8.4 Removing and installing rear wheel housing liner”,
page 379
8.1 Assembly overview - front wheel housing liner
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8.2 Assembly overview - rear wheel housing

liner
Note
♦ The illustrations show the left-hand side. The right side is anal‐
ogous.
♦ Minor differences (bolt quantity) may be encountered during
repair work, depending on vehicle model.
♦ Different versions depending on model, for allocation refer to
⇒ Electronic Parts Catalogue (ETKA) G. . Volkswagen
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8.3 Removing and installing front wheel

housing liner
8. Wheel housing liner 377

Note
♦ Removal and installation is described for the front left wheel housing liner only. Removal and installation of
the right front wheel housing liner are similar.
♦ The removal and installation procedures for front wheel housing liner may have to be revised slightly de‐
pending on model variations.
satelettronica
AG. Volkswagen AG d
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Removing
– Unclip spreader clips -4-.
– Detach ABS line from front wheel housing liner -1-.
– Take rear wheel housing liner -1- out of wheel housing.
Installing
Install in reverse order of removal, observing
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Before installing the front wheel housing liner, inspect the fastening elements, and renew them if necessary.
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Specified torques
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♦ ⇒ “8.1 Assembly overview - front wheel housing liner”,
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page 376
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8.4 Removing and installing rear wheel
es, in part or in w
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housing liner
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Note
♦ Removal and installation are described only for the rear left side. Removal and installation of the right side
is similar.
♦ Minor model-specific deviations (bolt quantity) may be encountered during removal and installation of the
rear wheel housing liner.
8. Wheel housing liner 379

satelettronica
AG. Volkswagen AG d
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– Release clamping washer -5- using a screwdriver.

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Before installing the rear wheel housing liner, inspect fastening elements, and renew them if necessary.
Specified torques
♦ ⇒ “8.2 Assembly overview - rear wheel housing liner”,
page 377

9 Lettering and emblems

olkswagen AG
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⇒ “9.1 Assembly overview - lettering
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⇒ “9.1.1 Assembly overview - lettering and emblems, rear lid”,
page 381
⇒ “9.1.2 Assembly overview - lettering and emblems, wing doors”,
rrectness of i
page 383
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⇒ “9.1.3 Assembly overview - lettering and emblems, dropside

vehicle”, page 384
nform
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9.1.1 Assembly overview - lettering and emblems, rear lid
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9. Lettering and emblems 381

General body repairs,enexterior
AG. Volks-wEdition
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⇒ page 385
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9.1.2 Assembly overview - lettering and emblems, wing doors
Note
(ETKA) .
1 - Badge
❑ The badge cannot be re‐
moved without becom‐
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2 - Lettering
⇒ page 385
3 - Lettering
satelettronica
designation
⇒ page 385
AG. Volkswagen AG d
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9.1.3 Assembly overview - lettering and emblems, dropside vehicle
Note
(ETKA) .
1 - Lettering
designation
⇒ page 385
2 - Lettering
⇒ page 385
satelettronica
AG. Volkswagen AG d
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9.2 Dimensions - lettering and emblems on

rear
⇒ “9.2.1 Dimensions for lettering, rear lid”, page 385
⇒ “9.2.2 Dimensions for lettering, wing doors”, page 386
⇒ “9.2.3 Dimensions for lettering, dropside vehicles”, page 388
9.2.1 Dimensions for lettering, rear lid
Note
(ETKA) .
1 - Lettering
❑ Model designation
❑ Dimension a = 20 mm,
from corner of rear lid to
satelettronica
start of lettering
❑ Dimension b = 35 mm,
bottom edge of rear lid
to bottom edge of letter‐
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2 - Lettering
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❑ Dimension d = 24 mm, AG. Volkswagen AG d
from corner of rear lid to agen oes
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Transporter 2016 ➤ n AG. Volkswagen AG do
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Dimensions for lettering, wing doors as of model year 2017
Note
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AG. Volkswagen AG d
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9.2.3 Dimensions for lettering, dropside vehicles
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9.3 Renewing lettering and badges at rear

⇒ “9.3.1 Fitting instructions”, page 388
⇒ “9.3.2 Renewing emblems for rear lid”, page 389
9.3.1 Fitting instructions


♦ The badge cannot be removed without becoming damaged.

♦ If a badge is being fitted for the first time on a new vehicle or
AG. Volkswagen AG d
a newly painted surface, observe the procedures described lkswin
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9.3.2 Renewing emblems for rear lid
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♦ The badge cannot be removed without damage.

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9.4 Renewing lettering and badges on sides
nform
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⇒ “9.4.1 Renewing badges on B-pillar”, page 390

m
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⇒ “9.4.2 Renewing letterings at the B-pillar”, page 391

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The badge cannot be removed without becoming damaged.
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⇒ Paintwork manual; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒
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rrectne
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es, in part or in w
t to the co
If a lettering is installed for the first time on a new vehicle or on
newly painted surfaces, follow the procedure in ⇒ Paintwork
manual; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Decorative trims
rrectness of i
and film .
l purpos
If a lettering is removed and reinstalled, only use adhesive re‐

mover to remove the adhesive remains. nform
ercia
Remove any glue residue from adhesive tape using adhesive strip
remover - VAS 6349- .
m
a
com
tion in
Ensure that the adhesive surfaces are free of dust and grease.
r
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Apply lettering immediately after cleaning.

do
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SIX lettering Cop py
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Removing
p by
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– Heat SIX lettering using hot air blower - V.A.G 1416- and pull
Prote AG.
it off.

Installing
– Remove protective paper from application film.
– Align application film -1- on door and apply.
♦ Dimension -a- = 31 mm
♦ Dimension -b- = 14 mm
– Pull off application film, lettering remains on door.
JOIN lettering
Removing
– Heat JOIN lettering using hot air blower - V.A.G 1416- and pull
it off.
Installing
satelettronica
– Remove protective paper from application film.
– Align application film -1- on door edges -2- and apply.
– Pull off application film, lettering remains on door.
9.5 Removing and installing lettering and

emblems for radiator grille
olkswa AG. V gen AG
agen does
Removing olksw not
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Note au ra
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The radiator grille emblem cannot be removed without damage.

an
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ab
pe
– Remove radiator grille -1- ⇒ page 308 .

ility
ot
wit
, is n
– Release locking lugs -3- on rear (qty. 8).

h re
hole
spec
– Push emblem -2- out of radiator grille -1-.

es, in part or in w
t to the co
Installing
rrectness of i
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Cop py
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Prote
393
AG.
9. Lettering and emblems
– Push emblem -2- in -direction of arrow- into radiator grille -1-

until retaining hooks can be heard to engage.
– Install radiator grille -1- ⇒ page 308 . AG. Volkswagen AG d
agen oes
olksw not
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satelettronica
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Prote AG.

10 Special add-on parts

⇒ “10.1 Assembly overview – special add-on parts”, page 395
10.1 Assembly overview – special add-on parts
1 - Front spoiler
⇒ page 310
2 - Spreader rivets
❑ Qty. 10
3 - Badge
4 - Rear spoiler
⇒ page 310
5 - Spreader rivets
satelettronica
❑ Qty. 6
6 - Bracket
❑ Qty. 3
7 - Spreader rivets
❑ Qty. 2 for each bracket
8 - Bolts AG. Volkswagen AG d
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❑ Qty. 3 olksw not
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❑ 4 Nm o rise nte
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9 - Side member
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❑ Rear left
un
pt
an
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ab
⇒ page 326
pe
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10 - Bolt
wit
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❑ 4 Nm
hole
spec
es, in part or in w
11 - Decorative strip
t to the co
❑ Remove and install to‐

gether with side mem‐
ber trim at front and rear
rrectness of i
12 - Side member trim

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❑ Front left
nform
ercia
13 - Bolt
m
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❑ 2 Nm
n in
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10. Special add-on parts 395

11 Load floor body

⇒ “11.1 Contact corrosion”, page 396
⇒ “11.2 Assembly overview - dropside body”, page 396
⇒ “11.3 Assembly overview - load floor and side boards/tail
board”, page 397
⇒ “11.4 Assembly overview - skid plate”, page 401
⇒ “11.5 Assembly overview - rear wheel housing”, page 403
⇒ “11.6 Assembly overview - tank trim”, page 404
11.1 Contact corrosion

The add-on parts, side boards and tail boards of the dropside
model are made from aluminium.
When these parts are installed, special care must be taken re‐
garding contact corrosion.
Contact corrosion can occur if unsuitable fastening elements
(bolts, nuts, washers and pop rivets) are used.
satelettronica
olkswagen AG
en AG. V
For this reason, only connecting elements with aolspecial
ksw
ag surface does
not
coating (Dacromet) have been fitted. ed
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ara
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These elements can be recognised byautheir
tho green colour. eo
ra
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If there is any doubt about the suitability of parts, a general rule
ce
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un
is to use new parts.
pt
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Note
ot
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♦ Use only genuine parts!
hole
spec
es, in part or in w
♦ Accessories must be approved by Volkswagen AG!

♦ Damage resulting from contact corrosion is not covered by the t to the co
warranty.
rrectness of i
11.2 Assembly overview - dropside body

l purpos
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tion in
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Cop py
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Prote AG.

1 - Load floor body

2 - Vehicle frame
3 - Bolts
❑ 50 Nm
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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pt
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11.3 Assembly overview - load floor and side

wit
, is n
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boards/tail board
hole
spec
es, in part or in w
⇒ “11.3.1 Assembly overview - load floor and side boards/tail

t to the co
board”, page 397

⇒ “11.3.2 Assembly overview - tailboard”, page 399
rrectness of i
⇒ “11.3.3 Assembly overview - add-on parts on side boards”,

l purpos
page 400
11.3.1 Assembly overview - load floor and side

nform
ercia
boards/tail board
m
at
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ion
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or
Note
his
ate
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cum
Different versions depending on model, for allocation refer to ⇒

for
en
g
Electronic Parts Catalogue (ETKA) .

n
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Prote AG.
11. Load floor body 397

1 - Load floor
base of 3,400 mm
❑ Adapt for vehicles with
wheelbase of 3,000 mm
and double cab using
workshop equipment
2 - Fastening ring
3 - Cargo bed frame
base of 3,000 mm,
3,400 mm and double
cab
4 - Threaded plate
❑ For bolting on the hinge
mountings
5 - Pop rivet
ers - VAS 5072- wage es n
satelettronica
olks ot g
yV ua
6 - Step ir se
d b ran
tee
o
❑ For tailgate auth or
ac
ss
❑ Secured with 6 pop riv‐
ce
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un
ets
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7 - Tailgate
erm
ab
ility
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❑ Material: Aluminium
wit
is n
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8 - Buffer stop
ole,
spec
❑ Qty. 2
t to the co
9 - Buffer stop
❑ Qty. 4
rrectne
10 - Stop profile
❑ Left and right at front
ss
❑ Left and right at rear
o
cial p
❑ Secured with 5 pop rivets f inform

mer
11 - Cover
atio
om
n
c
12 - Hinge mounting
i
or
n thi
te
sd
❑ Left and right

iva
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13 - Locking ring
fo
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❑ For side board at front on right and at rear on left
Co
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14 - Bush Prote
cted AG.
agen
❑ For hinge bearing, tailgate

15 - Hinge bearing, tailgate
❑ Left and right
16 - Tailgate
❑ Left and right
❑ 2,574 mm for vehicles with a wheelbase of 3,000 mm
❑ 2,933 mm for vehicles with a wheelbase of 3,400 mm
❑ For double cab, on left and right, 2,163 mm

17 - Locking ring
❑ For side board at front on left and at rear on right
18 - Front board
11.3.2 Assembly overview - tailboard
Note olkswage es n
ot g
byV ua
d ran
ir se
Different versions depending
tho on model, for allocation refer to ⇒ Electronic
tee
or
Parts Catalogue (ETKA) .
au ac
ss
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un
pt
1 - Tailgate
an
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❑ Material: Aluminium
rm
ab
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2 - Buffer stop
wit
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3 - Locking ring
hole
spec
satelettronica
❑ For left and right on tail‐
es, in part or in w
t to the co
board
4 - Pop rivet
rrectness of i
❑ Qty. 5
l purpos
ers - VAS 5072-

5 - Bolt
nform
ercia
❑ 12 Nm
m
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com
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6 - Washer
n in
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7 - Ring nut
s
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❑ With retaining cable and

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8 - Bolt
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❑ 12 Nm
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9 - Washer
Prote AG.
10 - Ring nut
11 - Cover
12 - Bolt
❑ 21 Nm
13 - Hinge mounting
❑ Left and right
14 - Bush
15 - Step
❑ For tailgate
16 - Pop rivet
❑ Qty. 6
❑ Insert using pop rivet pliers - VAS 5072-

11.3.3 Assembly overview - add-on parts on side boards

n AG. Volkswagen A age G do
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1 - Tailgate ed ran
oris tee
th or
2 - Pop rivet au ac
ss
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nl
pt
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ers - VAS 5072-
an
itte
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ab
3 - Plank ramp
ility
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4 - Rotary fastener
, is n
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hole
5 - Solid rivet
spec
es, in part or in w
❑ Qty. 2
t to the co
Note
rrectness of i
The solid rivet can be compressed
l purpos
with 2 hammers - a 2-kg hammer as

a holding-up hammer and 500-g
hammer to shape the head.
nf
ercia
orm
satelettronica
m
6 - Hinge mounting
atio
om
n in
c
7 - Bolts
or
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❑ Qty. 2
sd
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❑ 10 Nm
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8 - Hinge bearing, tailgate
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9 - Bolts
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❑ Qty. 2 Prote
cted AG.
agen
❑ 10 Nm

11.4 Assembly overview - skid plate

⇒ “11.4.1 Assembly overview - skid plate for short wheelbase”,
page 401
⇒ “11.4.2 Assembly overview - skid plate for long wheelbase”,
page 402
11.4.1 Assembly overview - skid plate for short wheelbase
Note
1 - Skid plate
tion of travel
2 - Bolts
❑ Qty. 6
satelettronica
❑ 10 Nm
3 - Washers
❑ Qty. 12
4 - Nuts
❑ Qty. 6
❑ 10 Nm
AG. Volkswagen AG d
agen oes
olksw not
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ara
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aut ra
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nl
pt
du
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es, in part or in w
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c
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ate
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for
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Cop py
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rig ht
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Prote AG.

11.4.2 Assembly overview - skid plate for long wheelbase
Note
1 - Skid plate
2 - Bolts
❑ Qty. 6
❑ 10 Nm
3 - Washers
❑ Qty. 12
4 - Nuts
❑ Qty. 6
satelettronica
❑ 10 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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un
pt
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hole
spec
es, in part or in w
t to the co
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Cop py
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rig ht
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by lksw
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Prote AG.

11.5 Assembly overview - rear wheel housing
Note
1 - Rear wheel housing

2 - Nuts
❑ Qty. 4
❑ 4 Nm
3 - Washers
❑ Qty. 4
4 - Bolts
❑ Qty. 4
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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es, in part or in w
t to the co
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tion in
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403
agen
Prote AG.
11. Load floor body
11.6 Assembly overview - tank trim
Note
♦ Tank trim -1- is installed in dropside with long and short wheelbase.
♦ Before installing tank trim -1-, felt strips -4- must be checked.
1 - Tank trim
2 - Bolts
❑ Qty. 6
❑ 35 Nm
3 - Brackets
❑ Qty. 2
4 - Felt strip
❑ 5 felt strips per console
❑ Dimensions approx.
satelettronica
35 mm x 20 mm
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl
pt
du
an
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ility
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wit
, is n
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es, in part or in w
t to the co
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nf
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Cop py
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Prote AG.

12 Towing bracket
⇒ “12.1 Assembly overview - towing bracket”, page 405
⇒ “12.2 Removing and installing towing bracket”, page 408
12.1 Assembly overview - towing bracket

⇒ “12.1.1 Assembly overview - rigid towing bracket”, page 405
⇒ “12.1.2 Assembly overview - towing bracket, double cab and
⇒ “12.1.3 Assembly overview - towing eye”, page 408
12.1.1 Assembly overview - rigid towing bracket
Note
♦ The assembly overview refers to a rigid towing bracket. Assembly of removable towing bracket is similar.
♦ Minor differences may be encountered with the towing brackets depending on model year.
satelettronica
♦ The specified torques refer only to factory-installed towing brackets.
♦ Request torque specifications for other towing brackets from the manufacturers.
♦ Information on electrics can be found in ⇒. VoWorkshop
gen AG
lkswagen AGmanual; Current flow diagram; Towing mode .
d a oes
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y Vol gu
b ara
ed nte
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th
au ra
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nl
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wit
, is n
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es, in part or in w
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nf
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Prote AG.
12. Towing bracket 405

1 - Rigid towing bracket

⇒ page 408
2 - Bolts
AG. Volkswagen AG d
❑ Qty. 3 left lksw
agen oes
not
Vo gu
❑ Qty. 3 right d by ara
rise nte
❑ 90 Nm +120° utho eo
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nl
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satelettronica
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nf
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orm
m
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Prote AG.

12.1.2 Assembly overview - towing bracket, double cab and dropside
Note
♦ Minor differences may be encountered with the towing brackets depending on model year.
♦ The specified torques refer only to factory-installed towing brackets.
♦ Request torque specifications for other towing brackets from the manufacturers.
♦ Information on electrics can be found in ⇒ Workshop manual; Current flow diagram; Towing mode .
1 - Towing bracket
⇒ page 408
2 - Bolts
❑ Qty. 3 left
❑ Qty. 3 right
satelettronica
❑ 90 Nm +120°
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl
pt
du
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ility
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ate
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12.1.3 Assembly overview - towing eye
1 - Towing eye
⇒ page 408
2 - Bolt
❑ 60 Nm
3 - Mounting
❑ For rear silencer
wage es n
4 - Bolts yV
olks ot g
ua
d b
❑ Qty. 2 oris e ran
tee
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❑ 60 Nm au ac
ss
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nl
pt
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satelettronica
hole
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es, in part or in w
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nf
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by lksw
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Prote AG.
12.2 Removing and installing towing bracket

⇒ “12.2.1 Removing and installing rigid towing bracket”,
page 408
⇒ “12.2.2 Removing and installing towing bracket, double cab and
⇒ “12.2.3 Removing and installing towing eye”, page 413
12.2.1 Removing and installing rigid towing

bracket


AG. Volkswagen AG d
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olksw not
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au ra
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♦ The towing bracket is a safety component that only qualified
personnel are allowed to attach to the vehicle.
rrectness of i
♦ The retrofit installation of a towing bracket must comply with
l purpos
the towing bracket manufacturer's assembly instructions.

♦ All modifications to and conversions on the towing bracket are
nform
ercia
satelettronica
prohibited, they lead to the expiry of General Type Approval.
m
a
♦ Refer to manufacturer's assembly instructions for tightening
com
tion in
torques for other towing brackets.
r
te o
thi
s
♦ Installation and removal is identical for a towing bracket with
iva
do
r
removable ball hitch.

rp
cum
fo
en
ng
♦ In the case of the towing bracket with removable ball hitch, the
t.
yi Co
op
removable ball hitch is accommodated in the separate trans‐ C py
t. rig
gh
port container in the luggage compartment.
ht
pyri by
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Prote AG.

olkswagen AG
wag en AG. V
Transporter 2016
olks ➤
does
not
yV gu
General body
sed repairs, exterior - Edition 10.2019
b ara
n
ri tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
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ility
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es, in part or in w
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rrectness of i
l purpos
nform
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at
om
ion
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or
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ate
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or
satelettronica
f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Removing
– Remove rear bumper cover ⇒ page 241 .
– Remove socket.
– With the help of a second mechanic, pull rigid towing bracket
-1- off vehicle, holding bracket parallel to vehicle when doing
so.
Installing
Installation notes
Note
♦ Underbody protection (if present) in area of towing bracket contact surfaces must be removed.
♦ Contact surfaces of towing bracket must be free of sealing compound and wax accumulation.
♦ Corrosion protection measures must be carried out on bare metal body areas.
♦ Adherence to the standard, approved fastening points is required.

Specified torques
♦ ⇒ “12.1 Assembly overview - towing bracket”, page 405
12.2.2 Removing and installing towing bracket,

double cab and dropside
satelettronica
♦ The towing bracket is a safety component that only qualified
personnel are allowed to attach to the vehicle.
♦ The retrofit installation of a towing bracket must comply with
the towing bracket manufacturer's assembly instructions.
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12.2.3 Removing and installing towing eye

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Removing
– Undo and remove bolts -4- and place a support under rear
silencer.
– Undo and remove bolt -2- and remove towing eye -1- down‐
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Installing
– Push the tab on the towing eye -1- into the opening in the lon‐
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13.1.1 Assembly overview - closed bodies
Installation instructions
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5 - Spare wheel
6 - Bearing shaft
7 - Carrier
13. Spare wheel bracket 415

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14 Mudflap
⇒ “14.1 Assembly overview - mudflap”, page 417
14.1 Assembly overview - mudflap

⇒ “14.1.1 Assembly overview - front mud flaps”, page 417
⇒ “14.1.2 Assembly overview - rear mud flaps”, page 418
⇒ “14.1.3 Assembly overview - rear mud flaps, double cab and
14.1.1 Assembly overview - front mud flaps
Note
1 - Front mud flap
satelettronica
2 - Bolt
❑ 8 Nm
3 - Bolt
❑ 2 Nm
4 - Blind rivet nut
❑ Insert using pop rivet nut
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14. Mudflap 417

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8 - Bumper
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14.1.3 Assembly overview - rear mud flaps, double cab and dropside
1 - Wheel housing
❑ To install, drill holes
7 mm ∅ at existing
punched points.
2 - Bolts
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14. Mudflap 419

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Service

Service Department. Technical Information

58 - Rear doors, door components

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8056531C

1.1 Safety precautions when working on a high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Safety precautions when working in vicinity of high-voltage components . . . . . . . . . . . . . . 2

1.1 Assembly overview – lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.1 Overview of fitting locations - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.3 Removing and installing ignition key battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.4 Removing and installing sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.6 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

1.7 Removing and installing lower roller guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1.9 Removing and installing hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.3 Renewing pre-seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

3.4 Removing and installing additional lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4.1 Assembly overview - cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

4.5 Adjusting cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

4.6 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

4.7 Removing and installing door hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Removing and installing wind deflector

1.10 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

1.11 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

2.1 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1 Convertible top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.2 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

2 Bumper, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

2.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

2.3 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

6 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

3.7 Removing and installing wing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

3.8 Removing and installing guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

3.10 Removing and installing underbody heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

6 Trim film and protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

7 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

7.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

7.2 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

7.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

7.4 Removing and installing mirror trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

7.5 Removing and installing mirror cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

11.6 Assembly overview - tank trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

1.1 Safety precautions when working on a high-voltage system

vehicle is difficult to detect. There is a risk of parts of the body

becoming trapped or drawn in.

– Switch off ignition.

– Always store the ignition key outside the vehicle.

Risk of damage to high-voltage cables

Improper handling of high-voltage cables or high-voltage connec‐