K0051007220-General Body Repairs Exterior

Service
Workshop Manual
Golf 1998 ➤
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
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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 © 2015 Volkswagen AG, Wolfsburg K0051007220

Golf 1998 ➤
General body repairs, exterior - Edition 08.2003
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AG. Volkswagen AG d
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Contents
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50 - Body - front . . . . u.tho. . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.or. . . . . .............. 1
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1 Body - front ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . ................. 1
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Removing and installing lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Lock carrier - service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.4 Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.5 Wing dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.6 Assembly overview - noise insulation (petrol engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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1.7 Assembly overview - noise insulation (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ss
1.2 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.3 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.4 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
atio
1.5 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.6 Assembly overview - bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.7 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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2 Rear lid, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.3 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2.4 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.5 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Rear lid, Bora . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Removing and installing microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Rear lid, estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Removing and installing microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Removing and installing tank flap unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Removing and installing tank flap unit (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.5 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.7 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.8 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Contents i
Golf 1998 ➤
1.9 Removing and installing locking button for locking rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.10 Door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.11 Removing and installing additional seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Assembly overview for central locking and convenience system . . . . . . . . . . . . . . . . . . . . 53
2.2 Removing and installing batteries for key with remote control (non folding type) ▸ 04.01 . . 56
2.3 Removing and installing batteries for key with remote control (folding type) ▸ 04.01 . . . . 57
2.4 Removing and installing batteries for key with remote control (folding type) 05.01 ▸ . . . . 58
2.5 Adapting keys with remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.4 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.5 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.6 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.7 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.8 Fitting door window to window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.9 Door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1 Sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.4 Distinguishing features between sliding/tilting sunroofs made by Webasto and Rockwell
(Meritor) . . . . . . . . . . . . . . . . . . . . . .w.ag. e.n.A.G.. .Vo. l.ks.w.a.g.en. A. G. d. o.e. . . . . . . . . . . . . . . . . . . . . . . . 77
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2 Sliding/tilting sunroof with glassd bpanel yV (Webasto) . . . . . . . . . . . t.g.ua.r . . . . . . . . . . . . . . . . . . 79
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2.1 Assembly overview - sliding/tiltingtho
ris sunroof with glass panel . . . . . . . .te.e o. . . . . . . . . . . . . . . 79
2.2 Removing sliding/tiltingsssunroofau r
glass panel . . . . . . . . . . . . . . . . . . . . . . a.c. . . . . . . . . . . . . 80
2.3 Installing glass panel for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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2.4 Adjusting glass panel for sliding/tilting sunroof (height adjustment) . . . . . . . . . . . . . . . . . . 82

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2.5 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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2.6 Removing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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2.7 Removing sliding headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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2.8 Removing drive mechanism for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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2.9 Adjusting drive mechanism for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . 86

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2.10 Removing pre-selector control for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.11 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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2.12 Adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.13 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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2.14 Removing coulisse guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.15 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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3 Sliding/tilting sunroof with glass panel (Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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3.1 Assembly overview - sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . 93

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3.2 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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3.3 Installing glass panel for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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3.4 Adjusting glass panel for sliding/tilting sunroof (height adjustment) . . . . . . . . . . . . . . . . . . 96

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3.5 Adjusting panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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3.6 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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3.7 Removing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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3.8 Removing sliding headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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3.9 Removing drive mechanism for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.10 Adjusting drive mechanism for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . 100
ii Contents
Golf 1998 ➤
3.11 Removing pre-selector control for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.12 Checking parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.13 Adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.14 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.15 Removing coulisse guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.16 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.2 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.3 Removing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.4 Assembly overview - bumper carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5 Assembly overview - bumper cover, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Removing and installing bumper cover, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.7 Removing and installing adapter, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.8 Assembly overview - centre air intake and air guide, Golf R32 . . . . . . . . . . . . . . . . . . . . . . 112
1.9 Assembly overview - bumper carrier, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2 Rear bumper . . . . . . . . . . . . . . . . . . . .ag. e.n.A.G.. V. o. lk. s.w.a.ge. n. A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . 113
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2.1 Assembly overview - bumper cover olks
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2.2 Removing and installing bumper ris cover . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . .
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2.3 Assembly overview - bumper au
t carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a.c . . . . . . . . . . . . 115
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2.4 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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2.5 Removing and installing towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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2.6 Assembly overview - bumper cover, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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2.7 Removing and installing bumper cover, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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2.8 Removing and installing adapter, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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2.9 Assembly overview - bumper carrier, R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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spec
es, in part or in w
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
t to the co
1 Flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
rrectness of i
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
l purpos
1.3 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.4 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
nform
ercia
1.5 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.6 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
m
at
om
1.7 Assembly overview - side window, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

on
c
in t
r
1.8 Removing undamaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

o
his
ate
1.9 Removing damaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

do
priv
1.10 Installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

um
for
en
ng
1.11 Assembly overview - side window, estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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op py
1.12 Removing undamaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
. C rig
ht ht
rig
1.13 Removing damaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
py by
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by lksw
1.14 Installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
cted agen
Prote AG.
1.15 Assembly overview - rear window, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.16 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.17 Removing damaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.18 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.19 Assembly overview - rear window, Bora . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.20 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.21 Removing damaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.22 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.23 Preparing undamaged window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.24 Preparing new window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.25 Preparing new window without precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Contents iii
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byV ua
ed ran
Golf 1998
hor ➤
is tee
t or
General
au body repairs, exterior - Edition 08.2003 ac
ss
ce
e
nl
pt
du
1.26 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
an
itte
y li
1.27 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
erm
ab
ility
1.28 Minimum curing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
ot p
wit
1.29 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
, is n
h re
1.30 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
hole
spec
2 Door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
es, in part or in w
t to the co
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.2 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.3 Removing front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
rrectness of i
2.4 Adjusting door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
l purpos
2.5 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.6 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
nf
ercia
2.7 Removing and installing assembly carrier, rear door window and quarter light window . . 151
orm
m
2.8 Fitting door window to window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
atio
om
2.9 Electric window regulator with convenience function (automatic opening and closing) and
n in
or c
force limitation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
thi
te
sd
a
2.10 Overriding resistance in event of force limitation intervention . . . . . . . . . . . . . . . . . . . . . . 160

iv
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rp
cu
2.11 Removing and installing window regulator motor or assembly carrier with window regulator
o
m
f
en
ng
........................................................................ 161
t.
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2.12 Assembly overview - assembly carrier with window regulator . . . . . . . . . . . . . . . . . . . . . . 162
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2.13 Repairing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
p by
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66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
AG.
1 Removing and installing wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1.1 Front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.2 Rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.3 Removing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.4 Removing exterior mirror (mechanical type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3 Roof mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.1 Roof moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Roof rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2 Installing retaining bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6 Bump strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.1 Renewing side bump strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7 Special body parts, Golf GTI (132 kW) and Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.5 Front and rear spoiler (Golf GTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.6 Side skirt (Golf GTI, Golf R32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.7 Roof spoiler (Golf GTI, Golf R32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.8 Preparing body kit component for bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
7.9 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.10 Minimum curing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.11 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.12 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
iv Contents
Golf 1998 ➤
50 – Body - front
1 Body - front
1.1 Tools
Special tools and workshop equipment required
♦ Guide pins -3411-
AG. Volkswagen AG d
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1.2 Removing and installing lock carrier with attachments
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1. Body - front 1
Golf 1998 ➤
1 - Lock carrier with attach‐

ments
❑ Removing:
– Disconnect cable
⇒ Item 3 (page 2) on
lock and separate elec‐
trical connections.
– Separate connections
on headlight housings.
– Remove front bumper

and bumper carrier
⇒ page 106 .
– Disconnect hose for

headlight washer sys‐
tem at T-piece.
– Unbolt radiator and con‐

denser from lock carrier.
– Secure radiator and

condenser in engine
compartment ⇒ Heat‐
ing, air conditioner; Rep.
Gr. 87 .
AG. Volkswagen AG d
agen oes
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♦ Do not hang condenser up on ut ra
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pipes/hoses. s
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♦ Do not kink condenser pipes/ho‐
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❑ Installing:
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– Align lock carrier to lon‐
ole,
spec
gitudinal members and
between wings.
t to the co
Body gaps/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body gaps; Body, front
– Readjust headlights. rrectnes
2 - Bolt
s o
cial p
❑ Qty. 2
inform
❑ 8 Nm
mer
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3 - Bowden cable
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4 - Hole in side panel

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5 - Radiator and condenser

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6 - Bolt
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❑ Qty. 4
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❑ 8 Nm
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7 - Bumper carrier
8 - Bolt
❑ Qty. 4
❑ 20 Nm
9 - Guide pins -3411-
2 Rep. Gr.50 - Body - front

Golf 1998 ➤
1.3 Lock carrier - service position
AG. Volkswagen AG d
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es, in part or in w
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tion in
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– Remove front bumper cover ⇒ page 106

s
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– Disconnect Bowden cable on lock.

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t.
– Unscrew one bolt ⇒ Item 8 (page 2) each from the longitudinal op
yi Co
members and then screw guide pins -3411- in left and right
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longitudinal members in their place.
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– Unscrew bolts ⇒ Item 8 (page 2) and ⇒ Item 2 (page 2) and
cted agen
Prote AG.
pull lock carrier forwards in area of guide pins -3411- .
1. Body - front 3
Golf 1998 ➤
1.4 Assembly overview - front wing
1 - Wing
❑ Removing:
– Removing front bumper
⇒ page 106 .
– Remove wheel housing

liner ⇒ page 168 .
– Heat wing in area of A-

pillar with a hot air blow‐
er and pull off.
❑ Installing:
– Before screwing wing in
place, screws in contact
area should each be fit‐
ted with a zinc underlay
-AKL 381 035 50- .
2 - Bolt
❑ Qty. 9
3 - Spring clip
4 - Seal
5 - Bracket
❑ Bolted to front longitudi‐
nal member
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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tion in
r
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Prote AG.

Golf 1998 ➤
1.5 Wing dimensions
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es, in part or in w
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Distance between wings

m
Horizontal and vertical offset between wing tips:

a
com
tion in
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1. Body - front 5
Golf 1998 ➤
-a- = 0…2 mm
1.6 Assembly overview - noise insulation (petrol engine)
1 - Noise insulation
❑ For petrol engines
❑ Screw fastened and in‐
serted in front area in
lock carrier
2 - Bolt
❑ Qty. 2
3 - Retainer
❑ Qty. 4
4 - Bolt
❑ Qty. 4
AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
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Prote AG.

Golf 1998 ➤
1.7 Assembly overview - noise insulation (diesel engine)
1 - Noise insulation
❑ For diesel engines
❑ Screw fastened and in‐
serted in front area in
lock carrier
2 - Bolt
❑ Qty. 2
3 - Retainer
❑ Qty. 4
4 - Bolt
❑ Qty. 4
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
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rm
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es, in part or in w
t to the co
rrectness of i
l purpos
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tion in
r
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1. Body - front 7
Golf 1998 ➤
55 – Bonnet, rear lid

1 Bonnet
1.1 Assembly overview
1 - Bonnet
❑ Removing:
– Remove lines for wind‐
screen washer system
and washer jets.
– Disconnect gas strut

⇒ Item 3 (page 8) AG. Volkswagen AG d
agen
from bonnet. Volksw
oes
not
gu
by ara
d
– Unclip hinge cover rise nte
tho eo
⇒ Item 12 (page 8) s au ra
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and remove from hinge. s
ce
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un
pt
an
d
– Unscrew bolts
itte
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⇒ Item 10 (page 8)
erm
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ility
and take off bonnet.
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– Adjusting ⇒ page 9
ole,
spec
2 - Adjustment buffer
t to the co
❑ Can be screwed in or
out to adjust the bonnet
height in relation to the
rrectne
wings
3 - Gas strut
ss o
cial p
❑ Removing and installing

f in
⇒ page 9
form
mer
❑ Releasing gas
atio
m
⇒ page 16
o
n
c
i
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e
4 - Filler piece
t
sd
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o
pr
5 - Guide piece
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6 - Plenum chamber seal
Co
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❑ Pushed onto flange
rig
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co
7 - Clip
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8 - Hose/jet
❑ Removing ⇒ Electrical system; Rep. Gr. 92 ; Repairing windscreen washer system
9 - Cd seal
10 - Bolt
❑ 23 Nm
11 - Hinge
12 - Hinge cover
❑ Clipped
❑ Pull off at right angle
8 Rep. Gr.55 - Bonnet, rear lid

Golf 1998 ➤
1.2 Adjusting bonnet

– The bonnet can be aligned between the wings by moving the
hinges within the over-sized holes.
– The bonnet can be adjusted in height to the wings by means
of the adjustment buffers ⇒ Item 2 (page 8) .
Body gaps/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body gaps;
Body, front
– After installing or adjusting, carry out corrosion protection
measures on hinges and screws/bolts.
1.3 Removing gas strut

– Support bonnet.
– Lift up locking clip -1- using screwdriver and pull gas strut off
ball head pins -2-.
Note
If the gas strut is to be reused, do not prise locking clips -1- com‐
pletely out of the ball socket, otherwise they will be damaged.
1- Locking clip
2- Mounting bracket with ball head pin
3- Gas strut
AG. Volkswagen AG d
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1.4 Removing and installing Bowden cable

ab
ility
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spec
t to the co
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1. Bonnet 9
Golf 1998 ➤
1 - Bowden cable
❑ Renewing - Remove re‐
lease lever
⇒ “1.5 Removing and in‐
stalling release lever”,
page 11
2 - Grommet
3 - Spreader nut
4 - Release lever
⇒ page 11
5 - Bolt
6 - Bearing bracket
❑ Cable attached
7 - Bowden cable retainer
8 - Bonnet lock
⇒ page 12
AG. Volkswagen AG d
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nl
pt
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itte
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erm
ab
ility
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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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Prote AG.

Golf 1998 ➤
1.5 Removing and installing release lever
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spec
es, in part or in w
t to the co
rrectness of i
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Removing
nform
ercia
– Pull release lever -1- approx. 2 cm.

m
– Insert a small screwdriver in the gap between the release lever

com
tion in
-1- and clip -2-.

r
te o
thi
– Then let go of release lever and detach clip from release lever
s
iva
do
(clip falls behind trim).

r
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– Unclip trim -3- in centre at right angle out of mounting bracket

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and at bottom out of entry step trim. C py
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Installing
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– Clip trim -3- at bottom in entry step trim first. Then press upper
Prote AG.
clip in mounting bracket.

– Now the clip -2- is engaged completely in the release lever.
– Then press release lever on support in mounting bracket.
Before closing the bonnet, check the function of the release lever
and Bowden cable.
1. Bonnet 11
Golf 1998 ➤
1.6 Assembly overview - bonnet lock
1 - Bonnet lock
❑ Adjusting: within over-
sized holes
❑ Body gaps/shut lines
⇒ Body Repairs; Rep.
Gr. 00 ; Body gaps;
Body, front
❑ To remove bonnet lock,
radiator grille, bumper
and lock support must
be removed
⇒ page 12
2 - Release lever
❑ To remove, radiator
grille must be removed
⇒ page 108
3 - Bumper
⇒ page 106
AG. Volkswagen AG d
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ab
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1.7 Removing and installing bonnet lock

hole
spec
es, in part or in w
– Remove radiator grille ⇒ page 176

t to the co
– Remove bumper ⇒ page 106

rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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for
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Cop py
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rig ht
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cted agen
Prote AG.

Golf 1998 ➤
1.7.1 Removing lock support

– Remove 5 screws -arrows-.
– Take lock support -1- off lock carrier -2-.
AG. Volkswagen AG d
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un
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ab
ility
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spec
t to the co
rrectne
1.7.2 Removing bonnet lock
s
– Pull bonnet lock -1- forwards slightly. Using screwdriver -3-,
s o
cial p
f
unclip Bowden cable -2- off lock in direction of arrow.
inform
mer
– Separate connector for microswitch.
atio
m
Installation is carried out in the reverse order.

o
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Prote AG.
1. Bonnet 13
Golf 1998 ➤
2 Rear lid, Golf
2.1 Tools
♦ Socket driver -T10010-
♦ Setting gauge -3371-
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2.2 Assembly overview ss a ra
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un
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erm
ab
ility
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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
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pr
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fo
en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
1 - Rear lid
❑ Adjusting ⇒ page 16
Gr. 00 ; Body gaps;
Body, rear
AG. Volkswagen AG d
2 - Trim panel agen oes
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❑ Removing and installing d by ara
ise nte
⇒ General body repairs, hor eo
ut
interior; Rep. Gr. 70 ; ss a ra
c
Trim, rear lid; Removing
ce
e
nl
and installing rear lid
pt
du
an
lower trim
itte
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ab
ility
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hole
4 - Gas strut
spec
es, in part or in w
t to the co
⇒ page 16
❑ Releasing gas
⇒ page 16
rrectness of i
5 - Bolt
l purpos
❑ 22 Nm
nf
ercia
6 - Lock plate
orm
m
❑ Adjusting - within over‐
atio
m
sized holes
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Gr. 00 ; Body gaps;
o
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Body, rear
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7 - Cap t. C rig
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8 - Pop rivet nut
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Prote AG.
9 - Hexagon nut
❑ 24 Nm
10 - Hinge
11 - Bolt
❑ 10 Nm
2. Rear lid, Golf 15

Golf 1998 ➤
2.3 Removing gas strut

– Support rear lid.
– Lift up locking clip -2- using screwdriver and pull gas strut off
ball head pin -1-.
1- Combi-ball head, 15 Nm
2- Locking clip
3- Gas strut
4- Bolt
5- Ball head pin
Note
♦ If gas strut is to be reused, locking clip -2- must not be taken

out of ball socket completely, otherwise locking clip will be
damaged.
♦ To reduce the degree of opening of the rear lid, there is the
option of installing shorter gas struts (by 20 mm). In this way,
the opening height will be reduced to approx. 175 cm.
2.4 Releasing gas from gas strut

– Clamp gas strut in vice in area marked -x- = 50 mm.
kswage es n
WARNING byV
ol ot g
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o
Gas-strut should only be clamped in this area otherwise
auth
risk of or
ac
accident! ss
ce
le
un
pt
an
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itte
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– Saw through cylinder of gas strut within first third of cylinder's
rm
ab
pe
ility
overall length using piston rod end of cylinder as starting point.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Wear protective goggles when sawing.

♦ Cover area of saw cut with a cloth.
rrectness of i
♦ Dispose of oil and cloth in dedicated disposal system.

l purpos
2.5 Adjusting bonnet

nform
mercia
a
com
tion in
Note
r
te o
thi
s
iva
do
♦ The rear lid is adjusted correctly if the gaps/shut lines are even
r
rp
cum
all around, the lid is not too deepset or protruding and all con‐
fo
en
ng
tours align when the lid closed.

t.
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Cop py
. rig
♦ Vehicle must be on its wheels when adjustment is performed.
t
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Vo
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Prote AG.

Golf 1998 ➤
– Turn adjustment buffer by 90 degrees using a ring spanner (24

mm AF) and take out of shaped hole.
– Take rubber buffer -1- off adjustment buffer and loosen clamp‐
ing screw (hexagon socket head 3 mm) until detent slide can
be pulled out.
– Pull detent slide out of housing and set to dimension -a- = 12.5
mm.
Note
When new, the adjustment buffer is already set to a distance of

12.5 mm.
– Insert adjustment buffer and secure in shaped hole by

n AG. Volkturning
swagen AG
through 90 degrees. lkswage does
not
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ility
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hole
spec
es, in part or in w
t to the co
– Unscrew cap -1- out of pop rivet -2- (left and right).
– Close rear lid using light force in the middle while holding han‐
rrectness of i
dle in the pulled (open) position.

l purpos
– Adjust gap using setting gauge -3371- to 5 mm between rear

lid and side part.
nform
ercia
– Open rear lid again.

m
a
com
– The rear lid is now adjusted with a preload of approx. 3 mm.

ion in
r
te o
– Screw plugs in pop rivet (left and right).

thi
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Prote AG.

Golf 1998 ➤
– Screw in clamping screw -1- to dimension a = 25 mm.

– Check adjustment.
AG. Volkswagen AG d
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d by ara
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aut ra
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nl
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ility
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2.6 Removing and installing rear lid lock
h re
hole
spec
es, in part or in w
t to the co
1 - Retaining clip
2 - Handle
rrectness of i
❑ Removing:
l purpos
– Unclip rear lid trim (han‐

dle is secured by means
of cross-head screw).
nf
ercia
orm
– Unclip pull rod
m
atio
m
⇒ Item 5 (page 18) ,

o
n in
c
lever out retaining clip

or
thi
⇒ Item 1 (page 18) and
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take lock cylinder hous‐
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ing out of handle.
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– Separate connector for C py
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luggage compartment gh ht
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light and, if necessary,
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unclip actuator rod for
cted agen
Prote AG.
central locking.
– Unscrew Torx screws

and take handle out of
rear lid.
3 - Securing bolt for positioning

motor
❑ Loosen and tighten us‐
ing socket driver -
T10010-
4 - Central locking positioning
motor
❑ Removing:
– Separate connector
from positioning motor.
– Unscrew positioning
motor using socket driver -T10010- and release from rear lid.
5 - Pull rod
6 - Torx screw
7 - Actuator rod
❑ Press relay lever ⇒ Item 11 (page 19) against stop and insert actuator rod stress-free

Golf 1998 ➤
8 - Lock cylinder housing

❑ Removing:
– Unclip rear lid trim (handle is secured by means of cross-head screw).
– Unclip pull rod ⇒ Item 5 (page 18) , lever out retaining clip ⇒ Item 1 (page 18) and take lock cylinder
housing out of handle.
9 - Lock
❑ Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Removing and installing rear lid
trim; Removing and installing rear lid lower trim .
– Separate connector from lock.
– Unclip actuator rod ⇒ Item 7 (page 18) , remove bolt ⇒ Item 10 (page 19) and take lock out of rear lid.
❑ Installing - only with engaged rotary latch
AG. Volkswagen AG d
10 - Oval-head countersunk bolt agen oes
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❑ 20 Nm ed b ara
nte
ris
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11 - Relay lever aut ra
c
ss
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nl
pt
du
an
itte
2.6.1 Installing
y li
erm
ab
ility
ot p
– Engage retaining clip again.
wit
, is n
h re
– Bring lock cylinder housing into contact with handle trim and
hole
spec
engage in handle. Housing can be heard to lock in place.
es, in part or in w
t to the co
– Continue installation in reverse order of removal.
rrectness of i
l purpos
nform
mercia
at
om
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.

Golf 1998 ➤
2.7 Removing and installing lock cylinder housing
1 - Handle
2 - Guide sleeves
3 - Grip moulding
4 - Seal
5 - Retaining clip
AG. Volkswagen AG d
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6 - Shaft olksw not
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7 - Locking ring rise nte
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8 - Spring ss c
ce
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nl
pt
9 - Seal
du
an
itte
y li
erm
ab
ility
ot p
❑ Removing:
wit
, is n
h re
– Unclip rear lid trim (han‐
hole
spec
dle is secured by means
es, in part or in w
of cross-head screw).
t to the co
– Unclip pull rod for rear
lid lock (if necessary, ac‐
rrectness of i
tuator rod for central
locking), lever out re‐
l purpos
taining clip
take lock cylinder out of
nf
ercia
o
grip moulding
rm
m
atio
⇒ Item 3 (page 20) .
om
n in
or c
11 - Linkage clip
thi
te
sd
iva
❑ For rear lid lock

o
r
rp
cu
o
m
f
12 - Linkage clip
en
ng
t.
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❑ For positioning motor C py
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gh ht
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Vo
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cted agen
Prote AG.

Golf 1998 ➤
3 Rear lid, Bora
3.1 Tools agen

AG. Volkswagen AG d
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Special tools and workshop equipment requiredd by V gu
ara
rise nte
♦ Socket driver -T10010- utho 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
♦ Setting gauge -3371-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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Prote AG.
3. Rear lid, Bora 21

Golf 1998 ➤
1 - Rear lid
To adjust, proceed as per in‐
structions for Golf model
Gr. 00 ; Body gaps;
Body, rear
2 - Trim panel
⇒ General body repairs,
interior; Rep. Gr. 70 ;
Removing and installing
rear lid trim
4 - Hexagon nuts
❑ 22 Nm
5 - Hinge
6 - Bolt
❑ 22 Nm
7 - Rubber buffer
8 - Gas strut
⇒ page 16
❑ Releasing gas
⇒ page 16
olkswagen AG
en AG. V
9 - Lock plate ksw
ag does
not
y Vol gu
❑ Adjusting - withinised b over‐ ara
nte
sized holesut
hor eo
a ra
❑ Body gaps/shut
ss lines c
⇒ Body Repairs; Rep. Gr. 00 ; Body gaps; Body, rear
ce
le
un
pt
an
d
itte
10 - Bolt
y li
erm
ab
❑ 22 Nm
ility
ot p
wit
is n
11 - Lock plate
h re
ole,
❑ For USA only

spec
12 - Pop rivet nut

t to the co
❑ Insert using pop rivet nut pliers -V.A.G 1765 A-

13 - Index number backing plate
rrectne
❑ Only apply pressure to hatched area

s
❑ Replacement part has two foils. The first foil covers the adhesive surface, the second must be pulled off
s o
after assembly.
cial p
f inform
14 - Line
mer
atio
m
15 - Hinge cover
o
n
c
i
or
n thi
te
sd
iva
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pr
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en
ng
t.
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Cop py
t. rig
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Vo
o
by c lksw
cted agen
Prote AG.

Golf 1998 ➤
3.3 Removing and installing rear lid

agen
AGlock
. Volkswagen AG
do
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Vol ot g
d by ua
ran
e
1 - Lock cylinder housing tho
ris tee
or
au
❑ Removing and installing ss
ac
⇒ page 24
ce
e
nl
pt
du
an
2 - Handle
itte
y li
erm
ab
❑ Removing ⇒ General
ility
ot p
body repairs, interior;
wit
, is n
Rep. Gr. 70 ; Rear lid
h re
trim
hole
spec
es, in part or in w
– Remove screw
t to the co
⇒ Item 14 (page 24) ,
separate connector for
switch
rrectness of i
and take handle off rear
l purpos
lid.
nf
ercia
3 - Switch for rear lid lock re‐
or
lease -E165-
m
m
atio
m
4 - Rear lid
o
n in
or c
thi
e
5 - Lock
t
sd
iva
o
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o
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f
en
ng
t.
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Co
op py
trim t. C rig
gh ht
pyri by
– Separate connector
o Vo
by c lksw
cted
from lock.
agen
Prote AG.
❑ Unclip actuator rod

⇒ Item 11 (page 23) ,
unscrew hexagon nuts
and remove lock.
6 - Hexagon nut
❑ 7 Nm
7 - Relay lever with linkage clip
8 - Motor for rear lid lock release -V139-
❑ Removing ⇒ General body repairs, interior; Rep. Gr. 70 ; Removing and installing rear lid trim
– Separate connector from motor.
❑ Unclip actuator rods ⇒ Item 11 (page 23) and ⇒ Item 13 (page 23) .
– Unscrew hexagon nuts ⇒ Item 10 (page 23) and take off support bracket ⇒ Item 12 (page 23) .
– Unbolt motor for rear lid lock release ⇒ Item 8 (page 23) off support bracket.
9 - Relay lever
10 - Hexagon nut
❑ 7 Nm
11 - Actuator rod
❑ Press relay lever ⇒ Item 7 (page 23) against stop and insert actuator rod stress-free
12 - Support bracket
13 - Actuator rod
❑ Press relay lever with linkage clip ⇒ Item 7 (page 23) against stop and insert actuator rod stress-free

Golf 1998 ➤
14 - Bolt
❑ 7 Nm
1 - VW emblem
❑ Comprises of emblem
carrier and script
❑ To install VW emblem,
pull off protective foil
and bond to lock cylin‐
der housing using dou‐
ble-sided adhesive tape n AG. Volkswagen AG do
swage es n
❑ Also screwed to lock cyl‐ byV
olk ot g
ua
inder housing ir se
d ran
tee
⇒ Item 7 (page 24) utho
or
a ac
ss
ce
e
nl
pt
du
❑ Removing:
an
itte
y li
erm
ab
– Removing rear lid trim ⇒
ility
ot p
General body repairs,
wit
, is n
h re
Rear lid trim .
hole
spec
es, in part or in w
– Separate microswitch/
t to the co
wiring harness connec‐
tor.
rrectness of i
– Disconnect actuator rod
from relay lever.
l purpos
– Remove bolts
nform
ercia

(qty. 3).
m
at
om
io
– Pull lock cylinder hous‐
n
c
in t
or
ing with VW emblem out
his
ate
of rear lid. do
priv
cum
or
❑ Installing:
f
en
ng
t.
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op
Installation is carried out in the C py
t. rig
reverse order.
gh ht
pyri by
Vo
co lksw
by
cted
3 - Microswitch
agen
Prote AG.
❑ For vehicles with central locking

❑ For vehicles without central locking
❑ Allocation ⇒ Genuine Parts
❑ Removing and installing ⇒ page 25
4 - Linkage clip
❑ To remove actuator rod, release linkage clip and lift up
5 - Seal
❑ Bonded locally to lock cylinder housing
6 - Bolt
❑ Qty. 3
❑ 4 Nm
7 - Bolt
❑ Qty. 2

Golf 1998 ➤
❑ 0.3 Nm
3.5 Removing and installing microswitch
3.5.1 Removing
– Removing and installing lock cylinder housing -2- ⇒ page 24 . AG. Volkswagen AG d
agen oes
olksw not
– Disengage locking hook on microswitch -1-. d by
V gu
ara
ise nte
r
To do this, press locking hook downwards -arrow-. ut ho eo
ra
s a c
s
ce
e
nl
pt
du
an
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
– Disengage locking hooks -arrows- of microswitch -1- out of
lock cylinder housing -2-.
rrectness of i
– Take microswitch -1- off lock cylinder -2-.
l purpos
nf
ercia
orm
m
atio
om
n in
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te
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f
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ng
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op py
3.5.2 Installing
t. C rig
gh ht
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Vo
o
by c lksw
– Attach wires -1- and -2- in retainer -arrow- of microswitch -3-. Prote
cted AG.
agen

Golf 1998 ➤
– Engage locking hooks -arrows- of microswitch -1- in lock cyl‐

inder housing -2-.
– When doing this, ensure that microswitch is positioned at the

locking lugs -arrows- on the lock cylinder housing -1-.
– Before engaging microswitch, check that wiring is correctly at‐
tached in retainer of microswitch and lock cylinder. If this is not
the case, the wiring and/or microswitch could become dam‐ agen
AG. Volkswagen AG d
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aged when the microswitch is engaged. olksw not
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itte
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ab
ility
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– Engage microswitch -1- with lock cylinder housing -2-. Ensure
h re
ole,
that locking hook -arrow- engages correctly.
spec
– Install lock cylinder housing ⇒ page 24
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.

Golf 1998 ➤
4 Rear lid, estate
1 - Rear lid
Gr. 00 ; Body gaps;
Body, rear
2 - Trim panel
⇒ General body repairs,
Removing and installing
rear lid trim
4 - Gas strut
⇒ page 16
❑ Releasing gas
⇒ page 16
5 - Ball head pin
❑ 10 Nm
6 - Bolt AG. Volkswagen AG d
agen
❑ 22 Nm olksw
oes
not
byV gu
ara
d
7 - Lock plate orise nte
eo
h
ut
❑ Adjusting - within over‐ ss a ra
c
sized holes
ce
e
nl
pt
du
an
itte
y li
erm
ab
Gr. 00 ; Body gaps;
ility
ot p
Body, rear
wit
, is n
h re
8 - Cap
hole
spec
9 - Pop rivet nut
es, in part or in w
t to the co
10 - Hexagon nuts
❑ 22 Nm
rrectness of i
11 - Hinge
l purpos
12 - Bolt
❑ 10 Nm
nf
ercia
orm
13 - Index number backing plate

m
atio
m
❑ Only apply pressure to hatched area

o
n in
or c
❑ Replacement part has two foils. The first foil covers the adhesive surface, the second must be pulled off
thi
te
sd
a
after assembly.
iv
o
r
rp
cu
o
14 - Pop rivet nut

f
en
ng
t.
yi Co
❑ Insert using pop rivet nut pliers -V.A.G 1765 A- ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Rear lid, estate 27

Golf 1998 ➤
4.2 Removing and installing rear lid lock

⇒ page 29
2 - Handle
trim
– Remove screw
separate connector for
switch
and take handle off rear
lid.
3 - Switch for rear lid lock re‐

lease -E165-
AG. Volkswagen AG d
agen oes
4 - Bolt Volksw not
gu
by ara
❑ 7 Nm rised
nte
ho eo
ut
5 - Support bracket
ss a ra
c
ce
le
6 - Actuator rod
un
pt
an
d
itte
❑ Press relay lever with

y li
rm
ab
linkage clip
pe
ility

ot
wit
, is n
against stop and insert

h re
actuator rod stress-free

hole
spec
es, in part or in w
7 - Hexagon nut
t to the co
❑ 7 Nm
8 - Motor for rear lid lock re‐
rrectness of i
lease -V139-
l purpos
nform
ercia
trim
m
– Separate connector from motor.

com
tion in
r
te o
– Unclip actuator rod ⇒ Item 6 (page 28) from lock cylinder housing.
thi
s
iva
do
r
rp
– Unclip actuator rod ⇒ Item 9 (page 28) from motor for rear lid lock release.
um
fo
en
ng
t.
yi
– Unscrew hexagon nuts ⇒ Item 7 (page 28) and take off support bracket ⇒ Item 5 (page 28) .
Co
Cop py
t. rig
gh ht
yri
– Unbolt motor for rear lid lock release ⇒ Item 8 (page 28) off support bracket.
p by
o Vo
by c lksw
cted agen
Prote
9 - Actuator rod
AG.
❑ Press relay lever with actuator rod ⇒ Item 13 (page 29) against stop and insert actuator rod stress-free
10 - Bolt
❑ 22 Nm
11 - Lock
❑ Removing
– Removing rear lid trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Rear lid trim .
– Separate connector from lock.

Golf 1998 ➤
❑ Unclip actuator rod ⇒ Item 9 (page 28) , unscrew bolts ⇒ Item 10 (page 28) (qty. 2) and remove lock.
12 - Rear lid
13 - Relay lever with linkage clip
1 - VW emblem
❑ Comprises of emblem
carrier and script gen AG. Volkswagen AG d
wa oes
❑ To install VW olks
y V emblem,
not
b gu
ara
pull offrisprotective foil
ed
nte
andutbond
ho to lock cylin‐ eo
ra
der
s housing using dou‐
s a c
ble-sided adhesive tape
ce
e
nl
pt
du
an
❑ Also screwed to lock cyl‐
itte
y li
inder housing
erm
ab
ility
ot p
wit
, is n
h re
hole
❑ Removing:
spec
es, in part or in w
– Removing rear lid trim ⇒
t to the co
Rear lid trim . rrectness of i
l purpos
– Separate microswitch/
wiring harness connec‐
tor.
nform
ercia
– Disconnect actuator rod

m
at
om
from relay lever

ion
c
in t
or
his
e
– Remove bolts
at
do
riv

p
cum
(qty. 3).
for
en
ng
t.
yi Co
op
– Pull lock cylinder hous‐ C py
ht. rig
ing with VW emblem out rig ht
py by
of rear lid. co Vo
by lksw
cted agen
Prote AG.
❑ Installing:
Installation is carried out in the
reverse order.
3 - Microswitch
❑ For vehicles with central locking
❑ For vehicles without central locking
❑ Allocation ⇒ Genuine Parts
❑ Removing and installing ⇒ page 30
4 - Linkage clip
❑ To remove actuator rod, release linkage clip and lift up
5 - Seal
❑ Bonded locally to lock cylinder housing
6 - Bolt
❑ Qty. 3
❑ 4 Nm

Golf 1998 ➤
7 - Bolt
❑ Qty. 2
❑ 0.3 Nm
4.4 Removing and installing microswitch
4.4.1 Removing
– Removing and installing lock cylinder housing -2- ⇒ page 29
– Disengage locking hook -arrow- on microswitch -1-.
To do this, press locking hook downwards.
– Disengage locking hooks -arrows- of microswitch -1- out of

lock cylinder housing -2-.
– Take microswitch -1- off lock cylinder -2-. n AG. Volkswagen AG do
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
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
4.4.2 Installing
es, in part or in w
t to the co
– Attach wires -1- and -2- in retainer -arrow- of microswitch -3-.

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

Golf 1998 ➤
– Engage locking hooks -arrows- of microswitch -1- in lock cyl‐

inder housing -2-.
– When doing this, ensure that microswitch is positioned at the

locking lugs -arrows- on the lock cylinder housing -1-.
– Before engaging microswitch, check that wiring is correctly at‐
tached in retainer of microswitch and lock cylinder. If this is not
the case, the wiring and/or microswitch could become dam‐
aged when the microswitch is engaged.
– Engage microswitch -1- with lock cylinder housing -2-. Ensure

that locking hook -arrow- engages correctly.
– Install lock cylinder housing ⇒ page 29 .
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
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
o
by c lksw
cted agen
Prote AG.

Golf 1998 ➤
5 Tank flap unit
5.1 Removing and installing tank flap unit (Golf)
1 - Tank flap unit

❑ Removing:
– Unscrew tank cap.
– Press back lock release

rod by operating remote
release.
– Remove cross-head
screw
– Pull rubber part off fuel
tank filler and swing tank
flap unit out of side pan‐
el.
❑ Installing:
AG. Volkswagen AG d
agen oes
Assembly bracket and posi‐ Volksw not
gu
tioner element installed. d by ara
ise nte
or eo
h
ut
– Install tank flap unit (rub‐ ss a ra
c
ber part rolled up) with
ce
le
un
hinge side leading.
pt
an
d
itte
y li
rm
– Secure tank flap unit
ab
pe
ility
and assembly part.
ot
wit
, is n
h re
2 - Cross-head screw
hole
spec
3 - Tank flap cup
es, in part or in w
t to the co
(can only be removed as
part of tank flap unit) rrectness of i
❑ Press out securing pin in
l purpos
tank flap unit to remove

the tank flap
nform
ercia
4 - Drain hose
m
5 - Side panel
a
com
tion in
6 - Release rod
r
te o
thi
s
iva
7 - Tank flap positioner element

do
r
rp
cum
fo
8 - Seal
en
ng
t.
yi Co
op
9 - Assembly piece
C py
t. rig
gh ht
yri
❑ Pushed into side panel p by
o Vo
by c lksw
cted agen
10 - Rubber part Prote AG.

Golf 1998 ➤
5.2 Removing and installing tank flap unit (Bora)

AG. Volkswagen AG d
agen oes
olksw not
yV gu
1 - Tank flap unit ed b ara
nte
ris
❑ Removing: aut
ho eo
ra
ss c
– Unscrew tank cap.
ce
e
nl
pt
du
an
itte
– Press back lock release
y li
erm
ab
rod by operating remote
ility
ot p
release.
wit
, is n
h re
– Remove cross-head
hole
spec
screw es, in part or in w
t to the co
– Pull rubber part off fuel
tank filler and swing tank
rrectness of i
flap unit out of side pan‐
el.
l purpos
❑ Installing:
nf
ercia
Assembly bracket and posi‐
orm
tioner element installed.
m
atio
om
n in
c
– Install tank flap unit (rub‐

or
thi
e
ber part rolled up) with

t
sd
iva
hinge side leading.
o
r
rp
cu
o
m
f
en
ng
– Secure tank flap unit

t.
yi Co
op
and assembly part. C py
ht. rig
rig ht
py by
2 - Cross-head screw co Vo
by lksw
cted agen
Prote AG.
3 - Tank flap cup
(can only be removed as
part of tank flap unit)
❑ Press out securing pin in
tank flap unit to remove
the tank flap
4 - Assembly piece
❑ Pushed into side panel
5 - Seal
6 - Tank flap positioner element
7 - Securing bracket
8 - Release rod
9 - Rubber part
❑ Roll up to install
10 - Side panel
5. Tank flap unit 33

Golf 1998 ➤
57 – Front doors, door components, central locking

1 Front door
1.1 Tools
AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
equipment required byV gu
ara
ed
ris nte
o
♦ Socket driver -T10011- aut
h eo
ra
ss c
ce
le
un
pt
an
d
♦ Assembly tool -T10034-

itte
y li
rm
ab
♦ Bit insert -3320/2- for
pe
ility
ot
-3320-
wit
, is n
h re
hole
spec
-3320-
es, in part or in w
t to the co
♦ Socket -3410-
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.
34 Rep. Gr.57 - Front doors, door components, central locking

Golf 1998 ➤
Note
♦ The door hinge bolts must always be replaced if loosened.

♦ The dash panel must be removed to remove and adjust the upper door hinges.
1 - Door
⇒ page 37
2 - Door handle with backing
plate
⇒ page 40
❑ Removing ⇒ page 39
4 - Cap
5 - Bolt
❑ 18 Nm
6 - Locking button
⇒ page 46
7 - Locking rod
8 - Bellows
wage es n
9 - Bolt yV
olks ot g
ua
d b
❑ 20 Nm o
ir se
ran
tee
th or
u
10 - Lock platess a ac
ce
e
nl
11 - Door lock
pt
du
an
itte

y li
erm
ab
⇒ page 42
ility
ot p
wit
12 - Bowden cable
, is n
h re
hole
13 - Interior release handle

spec
es, in part or in w
14 - Multi-point socket head

t to the co
bolt
❑ M8×28
rrectness of i
❑ 20 Nm + 1/4 turn (90°)

l purpos
further
❑ Always renew bolts after loosening
nform
ercia
15 - Multi-point socket head bolt

m
at
❑ M8×28
om
ion
c
❑ Remove only this bolt from hinge to remove door

in t
or
his
te
❑ 20 Nm + 1/4 turn (90°) further

a
do
priv
cum
or

f
en
ng
t.
yi Co
16 - Door hinge with door arrester t. Cop py
rig
gh
❑ Hinge is split
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
❑ M8×28
1. Front door 35
Golf 1998 ➤
❑ Installed from inside vehicle
❑ Removing A-pillar lower trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar and side panel trim
❑ M8×28
❑ M8×28
20 - Cap
21 - Bolt
❑ 13 Nm
22 - Door hinge
❑ Hinge is split n AG. Volkswagen AG do
lkswage es n
o ot g
yV
23 - Multi-point socket head ir se
d bolt
b ua
ran
o tee
❑ M8×22 auth or
ac
s
s
ce
le
un
pt
❑ To loosen or tighten bolt, remove and install dash panel ⇒ General body repairs, interior; Rep. Gr. 70 ;
an
d
itte
Dash panel
y li
erm
ab

ility
ot p
wit
is n

h re
ole,
spec

❑ M8×28
t to the co

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

Golf 1998 ➤
1.3 Removing and installing door
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
wit
, is n
h re
hole
spec
– Remove A-pillar lower trim -5- ⇒ General body repairs, inte‐

es, in part or in w
t to the co
rior; Rep. Gr. 70 ; Pillar and side panel trim; Removing A-pillar
lower trim .
– Separate connectors -6- on A-pillar.
rrectness of i
– Pull bellows -3- off A-pillar. Pull wiring out of opening -arrow-
l purpos
in pillar.
– Lever off cap -2- and unscrew bolt -1- from upper hinge pin.
nform
ercia
Torque setting: 13 Nm
m
at
om
– Unscrew lower bolt -4- from hinge using door alignment tool
ion
c
-3320- and bit insert -3320/2- . Torque setting: 20 Nm + 1/4

in t
or
his
te
turn (90°) further

a
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
Always renew this bolt. cop Vo
by lksw
cted agen
Prote AG.
– Lift door upwards out of hinge brackets.
1. Front door 37
Golf 1998 ➤
General body repairs, exterior - Edition 08.2003 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
1.4 Adjusting door tho
ir se tee
or
au ac
To ensure a correct door adjustment the door hinge must be loos‐
ss
ce
e
ened on the pillar. Other measures, such as raising the door, have
nl
pt
du
an
no effect. Subsequent pressure from above will cause the door to
itte
y li
sack again.
erm
ab
ility
ot p
The door alignment tool -3320- with bit -3320/2- is to be used for
wit
, is n
this.
h re
hole
spec
If it is necessary to loosen the upper door hinge on the A-pillar
es, in part or in w
from the inside, socket driver -3410- can be used. To do this, re‐
t to the co
move dash panel ⇒ General body repairs, interior; Rep. Gr. 70 ;
Dash panel; Removing and installing dash panel .
rrectness of i
1.5 Assembly overview - door handle and door lock
l purpos
1 - Door lock
nform
ercia
❑ The door lock can be re‐

moved only together
m
at
om
i
with the assembly carri‐
on
c
er.
in t
or
his
te

a
do
riv
⇒ page 42
p
cum
for
en
ng
2 - Cable
t.
yi Co
Cop py
❑ Lock release
t. rig
gh ht
pyri by
Vo
o
3 - Retaining bracket
c by lksw
cted agen
Prote AG.
❑ Bolted and riveted to
door lock
❑ Not supplied with door
lock
❑ This screw has been re‐
placed by a Torx screw.
The new tool was intro‐
duced as a result.
❑ Socket driver -T10011-
❑ Loosening this screw re‐
leases the lock cylinder
housing
⇒ Item 11 (page 39) ,
which can then be
pulled out of bearing
plate
❑ Bolt ⇒ Item 4 (page 38)
should not be screwed
in if the lock cylinder
housing is not in place.
The retaining ring could
fall into the door.
5 - Bearing plate
❑ Removing:
Door handle, lock cylinder housing and assembly carrier removed
– Remove cross-head screw ⇒ Item 6 (page 39) , push bearing plate backwards slightly and take out of
door.

Golf 1998 ➤
7 - Key
❑ With remote control (non-folding type)
❑ Renewing battery ▸ 04.01 ⇒ page 56
8 - Key
❑ With remote control (folding type)
❑ Renewing battery ▸ 04.01 ⇒ page 57
❑ Renewing battery 05.01 ▸ ⇒ page 58
❑ Adapting new or additional key to remote control ⇒ page 60 .
9 - Door handle with backing plate AG. Volkswagen AG d
agen oes
❑ Removing and installing ⇒ page 40 olksw not
V gu
d by ara
e nte
10 - Cap horis
eo
aut ra
11 - Lock cylinder housing ss c
ce
le
un
pt
an
d
itte
y li
❑ Lock cylinder is not available as a single replacement part
rm
ab
pe
ility
12 - Backing plate
ot
wit
, is n
h re
hole
spec
1.6 Removing and installing lock cylinder
es, in part or in w
t to the co
housing
rrectness of i
1.6.1 Removing
l purpos
– Lever out cap -3-.
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. Front door 39
Golf 1998 ➤
– Pull door handle -1- and hold. Unscrew bolt -3- using socket
wrench -T10011- ( socket wrench -T10072- was introduced
later for this purpose) onto stop. This releases the lock cylinder
housing.
Note
Unscrewing the bolt too far could result in the retaining ring being
separated from the bearing plate and subsequently falling into the
door.
– Pull lock cylinder housing -2- out of door handle bearing plate
of door handle at right angles.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
1.6.2 Installing d b ara
ise nte
or eo
h
ut ra
– Fit lock cylinder housing in bearing plate ofss door handle at right
a c
angles.
ce
le
un
pt
an
d
– Now screw bolt in bearing plate using the socket driver.

itte
y li
rm
ab
The door handle engages back into the lock cylinder housing with
pe
ility
ot
an audible click.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
During assembly, the door handle and lock cylinder housing
should be pressed against the door panel.
rrectness of i
l purpos
– Then perform remaining installation in reverse order of remov‐

al.
nform
ercia
• It is essential that a functional check is then carried out as an

incorrectly fitted and adjusted cable will mean the door cannot
m
be opened.
com
tion in
r
1.7 Removing and installing door handle

te o
thi
s
iva
do
r
Removing and installing lock cylinder housing ⇒ page 39 .

rp
cum
fo
en
ng
t.
1.7.1 Removing
yi Co
Cop py
ht. rig
rig ht
– Remove clip -1- out of door handle. py by
co Vo
by lksw
cted
– Swing door handle out of door.
agen
Prote AG.
1.7.2 Installing

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
eo
Golf 1998 ➤
h
s aut
General
ra
c body repairs, exterior - Edition 08.2003
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 Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Guide assembly tool -T10034- through the opening on the in‐

side of the door panel.
– To improve visibility, shine a pocket lamp inside the door.
– Hook assembly tool in spring -1- -arrow A-.
– Hook spring in door lock by pulling assembly tool -arrow B-.
– Swing door handle into door.
– Pull clip -1- into panel aperture and engage in door handle
-2-.
Note
Door handle -2- must be pressed against the door panel during
assembly.
Install lock cylinder housing ⇒ page 40 .

• It is essential that a functional check is then carried out with
the door open as an incorrectly fitted and adjusted cable will
mean the door cannot be opened.
1. Front door 41
Golf 1998 ➤
1.8 Removing and installing door lock

Attached to the assembly carrier are window regulator, door lock
and loudspeaker.
The door lock can be removed only together with the assembly
carrier.
The assembly carrier can only be removed if the door window is
unbolted from the clamping brackets of the window regulator. To
do this, lower door window to the height of the assembly holes in
assembly carrier and loosen clamping brackets.
If the door window cannot be lowered on the electric window ver‐
sion, first determine the cause of the fault.
To do this, use fault reader -V.A.G 1551- to interrogate fault mem‐
ory of convenience system (address word 46) ⇒ Body self-
diagnosis; Rep. Gr. 01 ; Convenience system; Interrogating fault
memory .
If an electrical fault has been caused by the window regulator
motor, the motor can be removed from the assembly carrier.
1.8.1 Removing
– Removing front door trim ⇒ General body repairs, interior;
Rep. Gr. 70 ; Removing and installing door trim .
– Removing and installing lock cylinder housing ⇒ page 39 .
– Remove clip -1- out of door handle.
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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Lever out cover caps -1-.

t to the co
– Lower door window until securing bolts for door window are
accessible.
rrectne
Note
ss o
cial p
If the work step cannot be carried out because there is a fault with
inform
the electric window motor, remove motor to slide window down.

mer
atio
om
– Loosen bolts -2- and press clamps apart.

n
c
i
or
n thi
e
– Slide door window upwards and hold in place (e.g. with adhe‐
t
sd
iva
sive tape).
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 1998 ➤
– Separate all wiring connectors -arrows-.
– Remove screws -2-.

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
– Remove bolts -arrows-. Pull assembly carrier at top off door,
hole
spec
raise and lift out of door to hinge side of door.
es, in part or in w
t to the co
– Turn assembly carrier and pull connector off door lock.
– Then disengage clips for electrical wiring on back of assembly
carrier.
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.
– Drive out clips -1- using a drift.
1. Front door 43
Golf 1998 ➤
– Disengage cable -2- out of clip -1-.

– Using a screwdriver -3-, lever off the door lock with the as‐
sembly carrier installation aid.
Note
The retaining bracket is not part of the items supplied with the
door lock. Secured to door lock with a bolt and a pop rivet.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Unclip securing rod -1-. To do this turn door lock in direction
ce
le
of arrow.
un
pt
an
d
itte
y li
– Unclip cable -2-.
rm
ab
pe
ility
– Turn cable nipple 90° and remove from eye.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.8.2 Installing
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.

Golf 1998 ➤
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
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull operating lever -1- in direction of arrow.

nform
ercia
– Using a screwdriver, tension the spring -2- mounted on the

m
at
om
door lock in the direction of the arrow and attach the lock lever
ion
c
to the spring.
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op
By hooking the operating lever in, the lock becomes locked. This prevents “incorrect” attachment of the Bowden
C py
t. rig
gh
cable later.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Insert assembly carrier in door.
1. Front door 45
Golf 1998 ➤
– Insert all bolts. Tighten bolts -1- and -2- in the sequence speci‐
fied.
– The remaining bolts can be tightened in any sequence.
– Press door window -3- in window channel -arrow- and tighten
clamping jaws via the bolts -4-.
• Torque setting: Plastic clamping jaws 9 Nm, aluminium clamp‐
ing jaws 11 Nm.
al.
• Then perform functional check.
1.9 Removing and installing locking button

for locking rod
AG. Volkswagen AG d
The description for removing and installing the locking
wage buttons
n oes
olks not
should be strictly adhered to. db
y V gu
ara
ise nte
r
If the instructions are not observed correctly,
ut
ho the locking rods in eo
ra
the front doors and the relays in thessrear doors could unscrew
a c
and/or the mountings could become damaged.
ce
le
un
pt
an
d
1.9.1 Removing
itte
y li
rm
ab
pe
ility
Front right and rear left doors
ot
wit
, is n
h re
– Release locking button by turning 180° anti-clockwise.
hole
spec
– Take locking button off upwards.
es, in part or in w
t to the co
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.

Golf 1998 ➤
1.9.2 Installing
Front right and rear left doors
– Fit locking button onto locking rod with mark -small dot on top-
towards vehicle interior.
– Press locking button on locking rod until the fluted section is
flush with the height of the door trim.
– Then turn the locking button 180° anti-clockwise.
The locking button could project approx. 0..2 mm out of the door
trim in the locked position.
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
1.9.3 Removing
Front left and rear right doors
rrectness of i
– Release locking button by turning 180° clockwise.
l purpos
– Take locking button off upwards. 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.
1. Front door 47
AG. Volkswagen AG d
agen oes
olksw not
Golf 1998 ➤ d byV gu
ara
e
General body repairs, exterior - Edition 08.2003 horis nte
eo
aut ra
ss c
1.9.4 Installing
ce
e
nl
pt
du
an
itte
Front left and rear right doors
y li
erm
ab
ility
– Fit locking button onto locking rod with mark -small dot on top-
ot p
wit
towards vehicle interior.
, is n
h re
hole
– Press locking button on locking rod until the fluted section is
spec
flush with the height of the door trim.
es, in part or in w
t to the co
– Then turn the locking button 180° clockwise.
The locking button could project approx. 0..2 mm out of the door
rrectness of i
trim in the locked position.
l purpos
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
1.10 Door seals

co Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
During production, a sealant is applied to the door seals, which

ility
ot p
are then placed on the door flange and rolled on.

wit
is n
h re
ole,
spec
Note
t to the co
♦ When seals are removed, the sealant will spread to the inside of the seal and the flanks will be bent out
slightly. If the seal is then refitted, a tight seal is not guaranteed.
rrectne
♦ Therefore each seal which is removed completely should be replaced by a so-called “tap-on” seal.
s
♦ If a seal has been partially removed, squeeze sides of seal together before refitting.
s 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.
1. Front door 49
Golf 1998 ➤
1.10.1 Assembly overview
1 - Door inner seal, 4-door

❑ Start at the upper radius
of the door aperture AG. Volkswagen AG d
when installing the seal agen oes
olksw not
V gu
by ara
2 - Door inner seal, 2-door rised
nte
ho eo
❑ Start at the B-pillar trim s aut ra
c
when installing the seal s
ce
e
nl
pt
3 - Door inner seal du
an
itte
y li
erm
ab
4 - Additional seal
ility
ot p
❑ Material - TPE
wit
, is n
h re
❑ Additional seal cannot
hole
spec
be removed without it
es, in part or in w
becoming damaged
t to the co
⇒ page 50
rrectness of i
5 - Door outer seal, 4-door
l purpos
6 - Clip
❑ Inserted in door seal
nform
ercia
7 - Clip
m
at
om
ion
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
yi Co
♦ The trim must be removed to re‐ Cop py
t. rig
move the door seals. opyri
gh by
Vo
ht
by c
♦ It may be necessary to loosen
lksw
cted agen
Prote
the dash panel depending on
AG.
space available in the dash pan‐

el area.
1.11 Removing and installing additional seal
1.11.1 Materials
♦ Spray-type sealant -D 476 KD9 A3-
♦ Primer -ALO 822 000 04- 1)
♦ Cleaning solution -D 009 401 04-
♦ Adhesive remover -D 002 000 10-
1) If desired, primer -D 822 150 A1- can also be used
1.11.2 Tools

Golf 1998 ➤
♦ Roller for fitting door insulation foil -3356-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
1.11.3 Removing
s a c
s
ce
e
nl
pt
du
– Pull off additional seal from the centre outwards in direction of
an
itte
y li
arrow
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
– Cut through sealant (adhesive) at ends of additional seal (only

upper part is visible in diagram) using a cutting tool.
m
at
om
io
– Remove rest/residue of adhesive tape from door.

n
c
in t
or
his
e
– In order to prevent the additional seal from accumulating ex‐

at
do
riv
cessively at the ends, the sealant must be cut down (do not
p
cum
or
remove down to the paintwork).

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Front door 51
Golf 1998 ➤
1.11.4 Installing
– Clean the ends of the additional seal using cleaning solution -
D 009 401 04- . The drying time is 5 minutes.
– Now spray the primer -ALO 822 000 04- thinly onto the surface
and observe the drying time of 10 minutes.
Before bonding additional seal, hold it against the door to ensure
it is of the correct size and length.
– Apply a small dot of sealant -D 476 KD9 A3- to the ends.
Note
Do not apply too much sealant. Remove excess material.
– Now pull protective foil off additional seal.
– Position the additional seal -1- at the top of the seam seal n AG. Volkswagen AG do
-arrow-. Press the additional seal onto the door from l wageto
kstop es n
o ot g
bottom. At the end of the additional seal is dimensionbyV -a- of ua
ed ran
approx. 21 mm at the door flange. ho ris tee
t or
au ac
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
– Roll the additional seal firmly in place using the door insulation
foil roller -3356- .
rrectness of i
– Remove any excess sealant from the door that may have been
pressed out.
l purpos
nform
ercia
Note
m
at
om
io
It may take up to a few days before the sealant is fully hardened.

n
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.

Golf 1998 ➤
2 Central locking olkswage

es n
ot g
byV ua
d ran
ir se tee
tho
or
2.1 Assembly overview for central locking and convenience system au ac
ss
ce
e
nl
pt
du
an
itte
1 - Coupling station
y li
erm
ab
❑ Installation position:
ility
ot p
Lower A-pillar, covered
wit
, is n
by trim in footwell
h re
hole
spec
– Remove A-pillar lower
es, in part or in w
trim ⇒ General body re‐
t to the co
pairs, interior; Rep. Gr.
70 ; Pillar and side panel
trim; Removing A-pillar
rrectness of i
lower trim .
l purpos
2 - Front right door control unit

❑ For convenience sys‐
nform
ercia
tem only
m
at
❑ Integrated into window
om
ion
regulator motor
c
in t
or
his
e
❑ Removing:
at
do
priv
c
– Removing door trim ⇒
um
for
en
g

n
t.
yi Co
interior; Rep. Gr. 70 ; . Cop py
Door trim .
t rig
gh ht
pyri by
Vo
co lksw
by
– Removing front assem‐ cted agen
Prote AG.
bly carrier ⇒ page 146 .
– Unbolt window regulator

motor ⇒ page 161 .
3 - Front right door lock

❑ Door lock is secured to
assembly carrier
❑ The electric central lock‐
ing is integrated in the
door lock module
❑ Removing:
– Removing door trim ⇒
interior; Rep. Gr. 70 ; Door trim .
– Removing front assembly carrier ⇒ page 146 .
– Removing door lock ⇒ page 42 .
❑ Installation position: B-pillar
– Removing B-pillar lower trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar and side panel trim .
5 - Rear right door control unit

❑ For convenience system only
❑ Integrated into window regulator motor
❑ Removing:
– Removing door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim
– Unbolt window regulator motor ⇒ page 161 .
2. Central locking 53
Golf 1998 ➤
6 - Rear right door lock

❑ Door lock is secured to assembly carrier
❑ The electric central locking is integrated in the door lock module
❑ Removing:
– Removing door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim
– Removing door lock ⇒ page 67
7 - Motor for tank flap lock -V155-

❑ Installation position: Under C-pillar trim
❑ To remove, the luggage compartment trim must first be detached up to the wheel housing ⇒ General
body repairs, interior; Rep. Gr. 70 ; Pillar and side panel trim .
❑ Can be unscrewed using socket driver -T10010- socket driver -T10010-
8 - Rear lid lock
❑ Bolted to rear lid
❑ Removing:
– Remove rear lid trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Rear lid trim .
– Unscrew rear lid lock.
9 - Rear lid positioning motor

AG. Volkswagen AG d
❑ Bolted to rear lid lksw
agen oes
not
o
❑ Can be unscrewed using socket driver -T10010- byV gu
ara
ed
ris nte
o eo
10 - Rear left door lock aut
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
❑ Removing:
erm
ab
ility
ot p
– Removing door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
❑ Installation position: In area of roof cross member, covered by roof trim
– Removing roof trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Roof trim; Removing and installing
rrectness of i
headliner .
l purpos
12 - Anti-theft alarm horn

❑ Installation position: In area of C-pillar covered by C-pillar trim
nform
mercia
13 - Rear left door control unit

at
om
io

n
c
in t
or
his
e

at
do
riv
❑ Removing:
p
cum
for
en
g
n
t.
yi Co
Cop py
ht. rig
– Removing rear assembly carrier ⇒ page 151 . rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
❑ Installation position: B-pillar
– Removing B-pillar lower trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar and side panel trim .
15 - Front left door lock


Golf 1998 ➤
❑ Removing:
16 - Controls
❑ Installed in door trim
❑ Removing:
17 - Front left door control unit

❑ Removing:
18 - Aerial for radio remote control agen

AG. Volkswagen AG d
oes
lksw not
❑ Under left A-pillar trim byV
o gu
ara
ed
❑ Removing: horis nte
e
t or
au a
– Removing A-pillar trim
ss ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar
c and side panel trim .
ce
le
un
pt
an
d
itte
y li
❑ Installation position: Lower A-pillar, covered by trim in footwell
rm
ab
pe
ility
ot
– Removing A-pillar bottom left trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar and side panel
wit
, is n
trim h re
hole
spec
20 - Central module
es, in part or in w
t to the co
❑ Bolted to bracket on steering column under dash panel

❑ To remove, remove lower steering column trim first ⇒ General body repairs, interior; Rep. Gr. 68 ;
Compartments, covers and trim; Removing trim under steering column
rrectness of i
21 - Bonnet lock
l purpos
❑ Contact switch for anti-theft alarm

❑ Installation position: In lock carrier
nform
ercia
– Removing bonnet lock ⇒ page 12

m
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.
Golf 1998 ➤
AG. Volkswagen AG d
agen oes
olksw not
2.2 Removing and installing batteries for y V gu
d b ara
ise nte
key with remote control (non folding or eo
th
au ra
type) ▸ 04.01 ss c
ce
e
nl
pt
du
an
1- Transmitter unit - upper part (turned-over)
itte
y li
erm
ab
2- Watch battery
ility
ot p
wit
, is n
3- Contact plate
h re
hole
4- Watch battery
spec
es, in part or in w
t to the co
5- Transmitter unit - lower part
6- Main key with variable code transponder
rrectness of i
In order to differentiate between a transponder key and a variable
code transponder key, note that the main key is stamped with “w”.
l purpos
nf
ercia
orm
m
atio
om
n in
2.2.1 Removing
or c
thi
te
sd
iva
– Insert a screwdriver in the slot between transmitter unit -1- and
o
r
rp
cu
key -2-.
o
m
f
en
ng
t.
yi
– Turn screwdriver in direction of arrow to separate transmitter
Co
Cop py
unit from key.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Lever the transmitter unit apart at the two locking lugs

-arrows-.
– Unclip upper battery -1- out of retainers -2- using a screwdriver

in direction of arrow.

Golf 1998 ➤
– The contact plate -1- has two straight edges. If these edges
are turned towards the locking lugs, the contact plate can be
removed.
– The contact plate can also be unclipped using a screwdriver.
– Now unclip the lower battery from the retainer using a screw‐
driver.
2.2.2 Installing
Note the polarity and correct installation position when installing
batteries.
– Place the battery -4- with the positive terminal downwards in
the sender unit (positive terminal is marked on housing).
– Now place the contact plate -3- on the battery -4-.
– Place battery -2- with the positive terminal downwards on the
contact plate and secure.
– Bring transmitter unit upper part -1-AGtogether
. Volkswagwith
en AGtransmitter
agen
unit lower part -5- and clipotogether. does
lksw no
V t gu
by
– Then clip transmitterriseunit
d to the key. ara
nte
tho eo
s au ra
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
2.3 Removing and installing batteries for

rrectness of i
key with remote control (folding type) ▸

04.01
l purpos
1- Transmitter unit - upper part

nform
ercia
2- Key with variable code transponder

m
at
om
io
3- Transmitter unit - lower part

n
c
in t
or
4- Battery
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Golf 1998 ➤
2.3.1 Removing
key -2-.
unit from key.
– Push transmitter unit apart in direction of arrow.
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
– Unclip batteries from retainers in direction of arrow using a

rm
ab
screwdriver.
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
ercia
2.3.2 Installing
m
a
com
tion in
r
Note the polarity and correct installation position when installing

te o
thi
batteries.
s
iva
do
r
rp
cum
– Place the battery with the positive terminal downwards in the

fo
en
g
transmitter unit (positive terminal is marked on housing).

n
t.
yi Co
Cop py
– Engage battery in transmitter unit by pressing down lightly.
t. rig
gh ht
pyri by
Vo
o
– Now bring cover and transmitter unit together (do not damage
c by lksw
cted agen
seal).
Prote AG.
– Then clip transmitter unit to the key.
2.4 Removing and installing batteries for key with remote control (folding type)
05.01 ▸

Golf 1998 ➤
1 - Key with variable code

transponder
2 - Transmitter unit - upper part
olkswagen AG
en AG. V
3 - LED ksw
ag does
not
y Vol gu
❑ When remote control ed
b is ara
nte
ris
operated LED ut
hoshould eo
light up. ss a ra
c
❑ If LED does not light up
ce
e
nl
pt
du
when remote control is
an
itte
y li
operated, the battery is
erm
ab
discharged and must be
ility
ot p
renewed.
wit
, is n
h re
4 - Battery
hole
spec
❑ Removing battery
es, in part or in w
t to the co
⇒ page 59
❑ Installing battery
⇒ page 60
rrectness of i
5 - Transmitter unit - lower part
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
o
by c lksw
cted agen
Prote AG.
2.4.1 Removing
key -2-.
unit from key.
lkswage es n
o ot g
Golf 1998 ➤ byV ua
d ran
ir se
General body repairs, exteriorth- Edition 08.2003
o tee
or
au ac
ss
– Press transmitter unit -1- apart using profile section of key
ce
e
nl
pt
-2-.
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unclip battery -1- in direction of arrow out of retainers -2- using
nform
ercia
a screwdriver.
m
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.
2.4.2 Installing
Note polarity and correct installation position when installing bat‐
tery.
– Place battery -1- with positive terminal downwards in trans‐
mitter unit -2- (positive terminal is marked on housing).
– Engage battery in transmitter unit by pressing down lightly.
– Now bring cover and transmitter unit together (do not damage
seal).
– Then clip transmitter unit to the key.
2.5 Adapting keys with remote control

Keys with remote control can be adapted using the vehicle diag‐
nosis, testing and information system -VAS 5051- .
– Select “guided fault finding” on diagnosis tester -VAS 5051- .
– Using the Go to key, select “Function/component selection”
and the following menu items in succession:
♦ Body
♦ General body repairs
♦ 01 - Self-diagnosis systems
♦ Convenience systems
♦ Convenience system functions
♦ Adapting keys with remote control

Golf 1998 ➤
58 – Rear doors, door components

lkswage es n
1 Rear door
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
1.1 Tools
ce
e
nl
pt
du
an
itte
y li
erm
ab
Special tools and workshop
ility
ot p
equipment required
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
-3320-
l purpos

-3320-
nform
ercia
♦ Socket -3410-
m
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
Vo
co lksw
by
cted agen
Prote AG.
1. Rear door 61
Golf 1998 ➤ AG. Volkswagen AG d
agen
General body
Vorepairs,
lksw exterior - Editionoe08.2003
s no
t
y gu
db ara
ise nte
r
tho eo
au ra
c
ss
The door hinge bolts must always be replaced if loosened.
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - Door
ility
ot p
wit
, is n
⇒ page 63
h re
hole
spec
es, in part or in w
plate
t to the co
⇒ page 65
rrectness of i
3 - Housing
l purpos
4 - Bolt
nf
ercia
o
❑ 20 Nm
rm
m
atio
m
5 - Cap
o
n in
or c
thi
6 - Locking button
te
sd
iva

o
r
rp
⇒ page 46 cu
o
m
f
en
ng
t.
yi Co
7 - Locking rod Cop py
t. rig
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8 - Relay lever p by
o Vo
by c lksw
cted agen
9 - Locking rod Prote AG.
10 - Bolt
❑ 20 Nm
11 - Lock plate
12 - Door lock
⇒ page 67
13 - Bowden cable
14 - Interior release handle
15 - Multi-point socket head
bolt
❑ M8×28
❑ Always renew after loosening
❑ M8×28
❑ Always renew after loosening
17 - Door hinge with door arrester
❑ Hinge is split
❑ M8×28
❑ Removing B-pillar lower trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Pillar and side panel trim
62 Rep. Gr.58 - Rear doors, door components

Golf 1998 ➤
❑ M8×28
21 - Cap
22 - Bolt
❑ 13 Nm
23 - Door hinge
❑ Hinge is split
AG. Volkswagen AG d
❑ M8×22 lksw
agen oes
not
Vo
d by gu
ara
rise nt
❑ Removing B-pillaruthlower
o trim ⇒ General body repairs, interior; eRep. eo
ra
Gr. 70 ; Pillar and side panel trim
a
❑ 20 Nm + /4 turn
1 s
s (90°) further c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
❑ M8×28
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3 Removing and installing door

rrectness of i
l purpos
– Remove B-pillar upper and lower trim ⇒ General body repairs,

interior; Rep. Gr. 70 ; Pillar and side panel trim .
nform
ercia
– Disconnect multi-pin connector under rubber boot -3-on B-pil‐

lar.
m
a
com
tio
– Lever off cover cap -2- using a screwdriver.

n in
r
te o
thi
– Remove bolt -1- from upper hinge.

s
iva
do
r
rp
um
fo
en
ng
t.
yi
– Remove lower bolt -4- from hinge.
Co
Cop py
t. rig
Torque setting: 20 Nm + 1/4 turn (90°) further
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Always renew this bolt.
– Lift door upwards out of hinge brackets.
1.4 Adjusting door

To ensure a correct door adjustment the door hinge must be loos‐
ened on the pillar. Other measures, such as raising the door, have
1. Rear door 63
Golf 1998 ➤
no effect. Subsequent pressure from above will cause the door to

sack again.
The door alignment tool -3320- with bit -3320/2- is to be used for
this.
If it becomes necessary to loosen the door hinge on the B-pillar
from the inside, bit extension -3410- can be used. To do this, B-
pillar lower trim must be removed ⇒ General body repairs,
interior; Rep. Gr. 70 ; Pillar and side panel trim . gen AG
. Volkswagen AG
wa does
olks not
1.5 Assembly overview - door handle
ise
db
y V and door lock gu
ara
nte
r
ho eo
aut ra
ss c
1 - Door lock
ce
e
nl
pt
❑ The door lock can be re‐
du
an
itte
moved only together
y li
erm
ab
with the assembly carri‐
ility
ot p
er.
wit
, is n
h re
hole
⇒ page 67
spec
es, in part or in w
2 - Cable
t to the co
❑ Lock release
rrectness of i
❑ Bolted and riveted to
l purpos
door lock
❑ Not supplied with door
nform
ercia
lock
m
at
4 - Bearing plate
om
ion
c
❑ Removing
in t
or
his
ate
Door handle, lock cylinder
do
priv
c
housing and assembly carrier
um
for
removed
en
ng
t.
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Cop py
– Remove cross-head ht. rig
rig ht
screw py by
co Vo
lksw
by
cted agen
Prote
push bearing plate
AG.
backwards slightly and

take out of door.
plate
⇒ page 65
7 - Cap
8 - Housing
9 - Backing plate
❑ This screw has been replaced by a Torx screw. The new tool was introduced as a result.
❑ Loosening this screw releases the lock cylinder housing ⇒ Item 8 (page 64) , which can then be pulled
out of the bearing plate ⇒ Item 4 (page 64) .
❑ Bolt ⇒ Item 10 (page 64) should not be screwed in if the lock cylinder housing is not in place. The retaining
ring could fall into the door.

Golf 1998 ➤
1.6 Removing and installing door handle

AG. Volkswagen AG d
agen oes
olksw not
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1.6.1 Removing o rised b ara
nte
h eo
ut
– Pull off door seal -1- in area
ss a of door handle. ra
c
ce
le
– Pull door handle -2- in direction of arrow and hold. Unscrew
un
pt
an
d
bolt -4- using screwdriver -T10011- ( -T10072- ) onto stop. This
itte
y li
releases the housing.
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Unscrewing the bolt too far could result in the retaining ring being
t to the co
separated from the bearing plate and subsequently falling into the
door.
rrectness of i
– Pull housing -3- at right angle to door out of door handle bear‐
l purpos
ing plate.
– Remove clip -1- out of door handle.
nform
mercia
– Swing door handle out of door.
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.
1.6.2 Installing
1. Rear door 65
Golf 1998 ➤
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
– Guide assembly tool -T10034- through the opening on the in‐

on
c
in t
side of the door panel.

or
his
ate
– To improve visibility, shine a pocket lamp inside the door.

do
priv
cum
or
– Hook assembly tool in spring -1- -arrow A-.

f
en
ng
t.
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op
– Hook spring into door lock by pulling assembly tool
C py
t. rig
gh
-arrow B-.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
– Swing door handle into door.

– Pull clip -1- into panel aperture and engage in door handle
-2-.
– Fit lock cylinder housing in bearing plate of door handle at right
angles.
– Now screw bolt in bearing plate using the socket driver.
The door handle engages back into the lock cylinder housing with
an audible click.
Note
Door handle -2- must be pressed against the door panel during
assembly.

al.
• It is essential that a functional check is then carried out as an
incorrectly fitted and adjusted cable will mean the door cannot
be opened.
1.7 Removing and installing door lock

and loudspeaker.
The door lock can be removed only together with the assembly
carrier.
The assembly carrier, however, can only be removed if the door
window is released from the window regulator. To do this, lower
window to height of installation hole in assembly carrier and re‐
move spreader pins. . Volkswagen AG
gen AG does
swa
If the door window cannot be lowered on the electric window
by
Vol ver‐
k not
gu
sion, first determine the cause of the fault. ris
ed ara
nte
tho eo
To do this, use fault reader -V.A.G 1551- to interrogate
s au fault mem‐ ra
c
s ce
le
diagnosis; Rep. Gr. 01 ; Convenience system; Interrogating fault

un
pt
an
d
memory .
itte
y li
erm
ab

ility
ot p

wit
is n
h re
ole,
1.7.1 Removing
spec
– Remove rear door trim ⇒ General body repairs, interior; Rep.

t to the co
Gr. 70 ; Removing and installing door trim .

– Remove housing.
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear door 67
Golf 1998 ➤

– Lower door window until spreader pin -2- and spreader plug
-3- are accessible in the cut-out of the window regulator.
Note
the electric window regulator, remove motor to slide window
down.
– Screw a 5 mm bolt (approx. 70 mm long) in the spreader pin

-2- and pull out from spreader plug -3-.
– Now screw an 8 mm bolt (approx. 80 mm long) into spreader
plug -3-. gen AG
. Volkswagen AG
d a oes
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y Vol gu
b ara
ed nte
Note oris eo
th
au ra
c
ss
When screwing in bolt, do not exert too great a pressure on the
ce
le
un
pt
spreader plug because otherwise the plug will fall into the door.
an
d
itte
y li
rm
ab
– Pull spreader plug out of window guide and thereby out of door
pe
ility
ot
window.
wit
, is n
h re
– When doing this, press window regulator cable -2- to side us‐
hole
spec
ing a screwdriver.
es, in part or in w
t to the co
– Pull off seal -1- from centre column to window aperture seal
-2-.
– Lever out cap -3-. rrectness of i
l purpos
– Then remove screw that becomes visible.

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.

Golf 1998 ➤
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
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 Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Using a screwdriver -1-, lift up locking lug -2- and take filler
piece -3- upwards out of window column -4-.
– Grasp inner window aperture seal -1- using pliers -2-. Then
move pliers in direction of arrow whilst lifting the window aper‐
ture seal -1- up out of door flange with light twisting motion at
the same time.
– To ease removal of the window aperture seal, use a wedge
-3- to supplement the pliers.
1. Rear door 69
Golf 1998 ➤
– Slide door window -1- upwards and take out of door towards
olks
wage es n
ot g
interior -arrow-. db
y V ua
ran
e
ris tee
tho or
au ac
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
– Pull off window guide -1- in upper area and remove cross-head
-2- in centre column.
rrectness of i
l purpos
Note
nform
ercia
♦ The cross-head screw -2- will gradually be discontinued. In‐

m
stead, the centre column will be clipped in at the top of the
at
om
io
door.
n
c
in t
or
his
e
♦ The remaining work sequence is the same.

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
. rig
– Remove hexagon bolt -1-.
ht ht
rig by
copy Vo
– Pull centre column -2- off quarter light window seal -3- and pull
by lksw
cted agen
Prote
downwards out of upper window guide.
AG.
– Take centre column -1- upwards out of door.

Golf 1998 ➤
– Remove bellows -1- from B-pillar.

– Separate connector -2-.
– Remove bolts -arrows-.

– Unscrew bolts -1- (for lock).
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Pull assembly carrier off door from above, lift up and lever out
un
pt
an
d
of door towards hinge side -arrow- of door.

itte
y li
erm
ab
– The release the two clips for the wiring off the reinforcement
ility
ot p
panel in the door and pull wire out of rubber boot.
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
1.7.2 Installing
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear door 71
Golf 1998 ➤
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
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia

or
m
m
atio
m
to the spring.
o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
cable at a later stage.
C py
ht. rig
rig ht
py by
co Vo
by lksw
– Guide wire through rubber boot in door and secure clips in door Prote
cted AG.
agen
panel.

Golf 1998 ➤
fied.
– Install door window, see instructions on how to fit door window
to window regulator ⇒ page 73 .
– Continue installation in reverse order of removal.
1.8 Fitting door window to window regulator
Note
lkswage es n
Vo ot g
When installing door ewindow,
d by always renew spreader plug uaand
ran
spreader pin.(partthno.
or -6N0 839 511- ).
is tee
or
au ac
ss
– Before renewing spreader plug and spreader pin, check glass
ce
e
nl
pt
for damage.
du
an
itte
y li
erm
– Insert spreader plug -2- in centre position with window re‐

ab
ility
moved.
ot p
wit
, is n
– Push spreader pin -1- flush into spreader plug -2-.

h re
hole
spec
– Guide window into door.

es, in part or in w
t to the co
– Insert door window -3- in the window lifting rail guide slot -4-.
– By applying slight pressure from above, engage glass in win‐
rrectness of i
dow regulator -arrow-.

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
1.9 Door seals
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear door 73
Golf 1998 ➤
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
During production, a sealant is applied to the door seals, which

, is n
h re
are then placed on the door flange and rolled on.

hole
spec
es, in part or in w
t to the co
Note
♦ When seals are removed, the sealant will spread to the inside of the seal and the flanks will be bent out
rrectness of i
slightly. If the seal is then refitted, a leak-free tight seal is not guaranteed.
l purpos
♦ Therefore each seal which is removed completely should be replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal together before refitting.
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.

Golf 1998 ➤
Note
The trim must be removed to remove the door seals.
1 - Door inner seal

❑ Start at the upper radius
of the door aperture
when installing the seal
2 - Door inner seal, 4-door
3 - Clip
AG. Volkswagen AG d
❑ Inserted in door seal lksw
agen oes
not
Vo gu
by
ised ara
nte
or eo
h
5 - Clip 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
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
o
by c lksw
cted agen
Prote AG.
1. Rear door 75
Golf 1998 ➤
60 – Sunroof
1 Sliding/tilting sunroof
1.1 Tools agen

AG. Volkswagen AG d
oes
olksw not
Special tools and workshoped by
V
equipment required gu
ara
ris nte
♦ Hooks for front
aut end -3370-
ho eo
ra
ss c
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
rrectne
1.2 General
ss o
cial p
Sliding/tilting sunroofs made by “Webasto” and “Rockwell (Meri‐ f inform
tor)” are installed.

mer
atio
m
The sliding/tilting sunroofs of both manufacturers are no different

o
n
c
in function or operation but there are distinguishing features which

or
n thi
e
help to tell them apart in the vehicle.

t
sd
iva
o
pr
Function ⇒ page 76 .
um
r
fo
en
ng
t.
yi
Generally, however, both sliding/tilting sunroofs differ in design
Co
op py
and function enough to warrant separate instructions for the pur‐
t. C rig
gh ht
yri
poses of repair. p by
o Vo
by c lksw
cted agen
In the event that a sliding/tilting sunroof requires complete re‐ Prote AG.
newal, the sliding/tilting sunroof can be replaced by either make.
For the purposes of repair and procurement of replacement parts,
it is always necessary to differentiate between both makes of
sliding/tilting sunroof.
Distinguishing features ⇒ page 77 .
1.3 Function
The sliding/tilting sunroof is opened and closed by turning the ro‐
tary switch or tilted and closed through pushing and pulling the
switch, with ignition switched on.
When the ignition is switched off, the sliding/tilting sunroof can still
be opened or closed until the driver door or passenger door is
opened.
On the rotary switch there are marks for preset opening positions
of the glass panel. It is possible, however, to open the sunroof in
any position by turning the switch clockwise.
76 Rep. Gr.60 - Sunroof

Golf 1998 ➤
Opening the sliding/tilting sunroof to switch position -1-, the so

called comfort position, largely reduces wind noises that can oc‐
cur in switch position -2-.
Opening/closing the sliding/tilting sunroof is carried out by actua‐
tion of the switch, i.e. pressing or pulling, or until the respective
end position of the glass panel is reached.
The sliding/tilting sunroof is equipped with a force limitation (anti-
trap) mechanism for the sliding function. If the sunroof encounters
an obstruction while closing, it will open automatically.
As of week 32 1998, a new motor and rotary switch are installed.
On models built from this date, the glass panel can also be tilted
open and closed using the rotary switch.
In addition, the glass panel is closed by pressing and holding the
rotary switch.
Note
The motor and switch can only be identified by the new part num‐
bers and should not be installed with older type components.
In addition, there is an emergency closure function. If problems

occur during closure, the sunroof can be forced shut by pressing
the pre-selector switch, which must be in the “sunroof closed” po‐
sition.
During the emergency closure function, the force limitation mech‐
anism is deactivated.
The sliding/tilting sunroof drive mechanism is protected against
overheating by a time limitation factor. The protective mechanism
activates when the sunroof is operated continuously for approx. AG. Volkswagen AG d
2 minutes. It is functional again once a predetermined coolinglksw
agen oes
not
down phase has elapsed. db
yV
o gu
a
e ran
ris tee
tho or
1.4 Distinguishing features between
ss sliding/ au ac
tilting sunroofs made by Webasto and

ce
e
nl
pt
du
an
Rockwell (Meritor)
itte
y li
erm
ab
ility
ot p
The following distinguishing features allow a means of identifica‐

wit
tion between the sliding/tilting sunroofs made by Webasto or
, is n
Rockwell (Meritor) for the purposes of repair. h re

hole
spec
1.4.1 Water channel connection

es, in part or in w
t to the co
– Open sliding/tilting sunroof and check water channel connec‐

tion.
rrectness of i
Webasto
l purpos
Water channel -1- is connected with glass panel at rear corner

areas.
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
o
by c lksw
cted agen
Prote AG.
1. Sliding/tilting sunroof 77
Golf 1998 ➤
Rockwell (Meritor)
AG. Volkswagen AG d
Water channel -1- is not connected with glass panellkat
swrear
agen corner oes
not
areas. db
y Vo gu
ara
e nte
ris
utho eo
ra
a c
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 lksw
by
cted agen
Prote AG.

Golf 1998 ➤
2 Sliding/tilting sunroof with glass pan‐

el (Webasto)
2.1 Assembly overview - sliding/tilting sunroof with glass panel
1 - Glass panel for sliding/tilting

sunroof (single pane safety
glass)
❑ Removing sliding/tilting
sunroof glass panel
⇒ page 80 .
❑ Installing sliding/tilting
sunroof glass panel
⇒ page 81
❑ Adjusting sliding/tilting
sunroof glass panel
⇒ page 82
2 - Panel seal
❑ Renewing panel seal
⇒ page 84
3 - Sliding headlining
❑ Removing and installing agen
AG. Volkswagen AG d
oes
sliding headlining olksw not
yV gu
⇒ page 85 . ed b ara
nte
ris
ho eo
4 - Slide aut ra
c
ss
5 - Lower trim
ce
e
nl
pt
du
an
❑ Up to week 35/02
itte
y li
erm
ab
ility
ot p
wit
6 - Upper trim
, is n
h re
hole
spec
es, in part or in w
t to the co
7 - Water channel
❑ Removed together with
rrectness of i
coulisse guide rail.
l purpos
8 - End piece
❑ To seal use butyl adhe‐
sive sealing cord -AKL
nf
ercia
450 005 05- .

rm
m
atio
m
9 - Bolt
o
n in
or c
❑ 3.5 Nm
thi
te
sd
iva
10 - Carrier unit
o
r
rp
cu
o
m
f
❑ Removing carrier unit ⇒ page 88

en
ng
t.
yi Co
op
❑ U-frame (with guide channels): If necessary, grease guide channels using only special grease G 000 C py
ht. rig
450 02. Otherwise correct operation may be impaired. rig ht
py by
co Vo
by lksw
11 - Electric drive Prote
cted AG.
agen
❑ Adjusting drive mechanism (0 position) ⇒ page 86
12 - Bolt
❑ 3.5 Nm
2. Sliding/tilting sunroof with glass panel (Webasto) 79

Golf 1998 ➤
13 - Crank for emergency operation

❑ Clipped into cover of electric drive mechanism
14 - Cover
15 - Spring
16 - Wind deflector
17 - Wind deflector mounting
18 - Torx screw AG. Volkswagen AG d
agen oes
ksw
❑ Torx T25 byV
ol not
gu
ara
ed
❑ 4.5 Nm horis nte
eo
aut ra
19 - Guide plate ss c
ce
e
nl
pt
du
an
itte
y li
20 - Slide with cable
erm
ab
ility
ot p
21 - Water channel slide
wit
, is n
h re
22 - Countersunk screws (microencapsulated)
hole
spec
❑ Always use new countersunk screws
es, in part or in w
t to the co
❑ 3.5 Nm
23 - Bellows
rrectness of i
❑ From week 36/02
l purpos
❑ Installing ⇒ page 82 nform

ercia
Note
m
at
om
io
Bellows and trim should not be in‐

n
c
in t
r
terchanged. Clearance between

o
his
te
mechanical parts may otherwise be

a
do
riv
impaired.
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
2.2 Removing sliding/tilting sunroof glass
rig ht
py by
co Vo
by lksw
panel cted agen
Prote AG.
– Slide sun blind/sliding headliner to rear.

– Tilt sunroof.
Vehicles up to week 35/02
– Unclip lower trim -1- in rear area -arrow-, slide forwards and
take off roof frame.
– Unclip upper trim -2- at front and centre and unhook at rear.
Vehicles from week 36/02
On vehicles from week 36/02, a bellows is installed in place of the
upper and lower trim.

Golf 1998 ➤
– Disengage bellows -1- out of securing rail -3-.

– Disengage bellows -1- at top rear out of glass panel for sliding/
tilting roof -2-.
– Unhook bellows -1- at top rear out of glass panel for sliding/
tilting roof -2-.
– Unclip bellows -1- at top rear out of glass panel for sliding/tilting
roof -2-.
– Take off bellows -1-.
Continued for all vehicles
– Remove securing screws -1- (Torx T25; 4.5 Nm). Do not re‐
move middle screw -2- - only loosen.
– Remove sliding/tilting sunroof panel upwards.
2.3 Installing glass panel for sliding/tilting

wage
sunroof
by
Volks es n
ot g
u
d ara
se nte
Panel must thbe
or installed in 0 position (panel closed).
i
e or
au ac
2.3.1 ss
Zero position:
ce
e
nl
pt
du
an

itte
y li
erm
ab
The square holes in the tilt levers should align with the recesses
ility
ot p
in the guide rails -arrow-.

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
The coulisse guide rail pin must align with the marking (lug) on
ion
c
the coulisse guide rail -arrow-.

in t
or
his
ate
If this is not the case, adjust parallel running ⇒ page 88 .

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.

Golf 1998 ➤
– Position sliding/tilting sunroof panel from above and screw in

securing screws (coulisse guide rail/panel).
– Lightly tighten securing screws -1- and -2- (Torx T25).
– Adjust sliding/tilting sunroof glass panel (height adjustment)
⇒ page 82 .
AG. Volkswagen AG d
agen oes
olksw not
Note d by V gu
ara
rise nte
tho eo
After adjusting panel height, tighten
ss a securing screws (4.5 Nm).
u ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Install upper and lower trim to match panel height adjustment.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Bellows and trim should not be interchanged. Clearance be‐
l purpos
tween mechanical parts may otherwise be impaired.

♦ Install bellows after panel height adjustment.
nform
mercia
at
om
io
2.4 Adjusting glass panel for sliding/tilting
n
c
in t
or
sunroof (height adjustment)
his
ate
do
priv
cum
for
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
The glass panel height adjustment is performed after the glass p by
co Vo
panel has been closed from slide open position.
by lksw
cted agen
Prote AG.
Zero position of sliding/tilting sunroof OK.

– Tilt sunroof.
– Unclip lower trim -1- in rear area -arrow-, slide forwards and
take off roof frame.

Golf 1998 ➤
. Volkswagen AG
do gen AG
– Disengage bellows -1-
Vol
kswout of securing rail -3-.es not
a
y gu
db a
– Disengage bellows
oris
e -1- at top rear out of glass panel forransliding/
tee
tilting roofaut-2-.
h or
a
ss c
– Unhook bellows -1- at top rear out of glass panel for sliding/
ce
le
un
pt
tilting roof -2-.
an
d
itte
y li
– Unclip bellows -1- at top rear out of glass panel for sliding/tilting
erm
ab
ility
roof -2-.
ot p
wit
is n
h re
ole,
spec
t to the co
– Loosen securing screws -3- (Torx T25; 4.5 Nm).
rrectne
– Close glass panel, open panel and close again (adhere strictly
to sequence to achieve a correct adjustment).
ss o
– Carry out height adjustment of glass panel at front and rear on
cial p
f in
both sides as follows:
form
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
Panel adjustment front:
gh ht
pyri by
Vo
co lksw
by
-a- = 0…1 mm lower than roof cted agen
Prote AG.
-Arrow- = Forwards
Panel adjustment rear:

-b- = 0…1 mm higher than roof
-Arrow- = Forwards
– Tighten screws for glass panel (4.5 Nm).
Always tighten left and right sides of glass panel symmetrically.
– Tilt sunroof.

Golf 1998 ➤
– Hook in upper trim -2- at rear and clip front and centre in.
– Slide lower trim -1- in direction of arrow into rear elongated
hole and clip front section in.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
♦ On vehicles from week 36/02, a bellows d is installed in place of
b ua
ran
ir se
the upper and lower trim. tho tee
or
au ac
ss
ce
e

nl
pt
du
an
itte
y li
erm
ab
– Engage clips of bellows -1- in glass panel for sliding/tilting roof
ility
ot p
-2-.
wit
, is n
h re
– Hook bellows -1- in at top rear of glass panel for sliding/tilting
hole
spec
roof -2-.
es, in part or in w
t to the co
– Engage bellows -1- at top rear of glass panel for sliding/tilting
roof -2-.
rrectness of i
– Engage bellows -1- to securing rail -3-.
l purpos
nf
ercia
orm
m
atio
m
2.5 Renewing panel seal

o
n in
or c
thi
e
– Remove glass panel for sliding/tilting sunroof ⇒ page 80 .

t
sd
iva
o
r
rp
cu
– Pull seal -1- off glass panel.
o
m
f
en
ng
t.
yi Co
– Press new seal into groove in glass panel -2-. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
To ease fitting of seal, apply soapy solution to edge of panel.
2.6 Removing wind deflector

– Open sliding/tilting sunroof completely.
– Push wind deflector -1- out downwards and towards the centre
of the vehicle -arrow- on both sides out of guide -2-.
– Take out wind deflector.

Golf 1998 ➤
2.7 Removing sliding headlining

. Volkswage
– Push sun blind backwards gen AG to ease nremoval.
aslightly AG do
es n
ksw
y Vol ot g
u
– Remove front screws ed
b -arrow- on left and right-hand sides.
ara Pull
nte
ris
out slide forwards
utho over the stop -1-. eo
ra
sa c
– Move sliding
s panel forwards.
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
– Remove rear screws -arrow- on left and right-hand sides. Pull
out slide to rear and remove sliding headlining -1-.
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
2.8 Removing drive mechanism for sliding/
by lksw
cted agen
Prote AG.
tilting sunroof
– Disconnect battery earth strap from battery.
– Unclip cover -1- for drive mechanism.
Note
Remove and install drive mechanism for sunroof only with sunroof
closed (zero position ⇒ page 86 ).
– Unclip and separate connector.
– Unscrew screws -arrows- and pull off drive mechanism for

The screws for the drive mechanism are microencapsulated and
must always be renewed (3.5 Nm).

Golf 1998 ➤
2.9 Adjusting drive mechanism for sliding/tilting sunroof (zero position)
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
It may be necessary to adjust the zero position if the drive mech‐

anism was not removed in the zero position or the sliding/tilting
sunroof was closed or opened by means of the emergency de‐
rrectness of i
vice.
l purpos
Drive mechanism removed but still connected electrically.

– Select automatic “open sunroof” function on rotary switch.
nf
ercia
– Select automatic “close sunroof” function on rotary switch.

rm
m
atio
m
– Select automatic “tilt roof” function on rotary switch.

o
n in
or c
thi

te
sd
iva
o
r
– Install drive in this position (zero position) with sliding/tilting

rp
cu
o
sunroof closed.
f
en
ng
t.
yi Co
op
From week 32/98, the “zero position” can be seen through an
C py
t. rig
gh
aperture in the motor (markings must align -arrow-).
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Golf 1998 ➤
e nte
horis General body repairs, exterior
eo - Edition 08.2003
aut ra
ss c
2.10 Removing pre-selector control for slid‐
ce
e
nl
pt
du
ing/tilting sunroof
an
itte
y li
erm
ab
– Unclip trim -1- in direction of arrow and remove.
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
m
– Remove screws -arrows- and remove pre-selector control.

o
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
o
by c lksw
cted agen
Prote AG.
2.11 Checking parallel running

2.11.1 Vehicles up to week 31/98


Golf 1998 ➤
2.11.2 Vehicles from week 32/98

2.12 Adjusting parallel running
Note
The parallel running adjustment can only be undertaken when the

drive and glass panel are removed (zero position).
– Removing sliding/tilting sunroof drive mechanism ⇒ page 85 .
2.12.1 Vehicles up to week 31/98

– Install drive mechanism in “zero position” (markings in aper‐
ture must align).
– Then check zero position.
en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
2.12.2 Vehicles from week 32/98

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
a
2.13 Removing and installing carrier unit

iv
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.

Golf 1998 ➤
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
Removing
nf
ercia
– Removing pre-selector control for sliding/tilting sunroof

rm
m
⇒ page 87 .
atio
om
n in
c
– Remove moulded headliner ⇒ General body repairs, interior;

or
thi
e
Rep. Gr. 70 ; Roof trim .

t
sd
iva
o
r
rp
cu
– Pull water drain hoses off carrier unit -1- -arrows-.

o
m
f
en
ng
t.
yi
– Unscrew bolts -2- and, with the help of a second mechanic,
Co
op py
remove carrier unit from vehicle.
t. C rig
gh ht
pyri by
Vo
Installing
co lksw
by
cted agen
Prote AG.
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– Align carrier unit in roof frame using cylindrical pins (drill bit
shank), 12 mm at front right and 10 mm at rear left. Carrier unit
must not be in contact with roof frame.
– Check correct routing of wiring and connections from electrical
consumers in roof and rectify as necessary.
– Tighten bolts (8 Nm) for carrier unit -1-, starting at sliding/tilting
sunroof drive mechanism -3- and moving backwards, alter‐
nating between left and right-hand sides.
– Fit water drain hoses -arrows-.

Golf 1998 ➤
– Fit connector for drive mechanism -3-.
2.14 Removing coulisse guide rail

– Remove carrier unit ⇒ page 88 .
– Removing sliding/tilting sunroof drive mechanism ⇒ page 85 .
– Unscrew end cap -1- from guide rail -2- as shown -arrows- and
then pull off.
Note
. Volkswagen AG
gen AG does
When installing, bond end cap -1- to guideolksrail using Butyl adhe‐
wa not
yV
sive sealing cord -AKL 450 005 05-se.d b gu
ara
nte
ri
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Push guide rail -1-, slide with cable -2- and water channel -3-
wit
, is n
together out of guide rails of carrier unit on the left and right-
h re
hand side at the same time and then remove.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Always renew guide with cable as a pair.
l purpos
nf
ercia
orm
m
atio
om
n in
c
2.15 Cleaning water drain hoses

or
thi
te
sd
iva
o
r
rp
cu
o
2.15.1 Front water drain hoses:

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Note
co Vo
by lksw
cted agen
Prote AG.
For cleaning, a locally manufactured tool made from a speedometer inner cable, approx. 2300 mm long is
recommended.

Golf 1998 ➤
1 - Front water drain hoses

The front water drain hoses are
routed in the A-pillars and fin‐
ish between the door and A-
pillar. They are cleaned from
the sliding/tilting roof panel
aperture.
2 - Conduit
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
2.15.2 Rear water drain hoses:
Note
recommended.
1 - Water drain hose

The rear water drain hoses are AG. Volkswagen
routed in the C-pillars andlkfin‐ wage
n AG do
es n
o s
ish behind the bumper d bycover
V ot g
ua
beneath the rear light
o
ir se cluster.
ran
tee
They are cleanedau from the bot‐
th or
ac
tom hose end. ss To do this, the
ce
bumper must be removed.
e
nl
pt
du
an
itte
y li
2 - Conduit
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 Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
3 Sliding/tilting sunroof with glass pan‐

el (Meritor)
3.1 Assembly overview - sliding/tilting sunroof with glass panel
1 - Glass panel for sliding/tilting

sunroof (single pane safety
glass)
❑ Removing sliding/tilting
sunroof glass panel
⇒ page 94 .
❑ Installing sliding/tilting
sunroof glass panel
⇒ page 95
❑ Adjusting sliding/tilting
sunroof glass panel
⇒ page 96
2 - Panel seal
❑ Adjusting panel seal
⇒ page 98 n AG. Volkswagen AG do
wage es n
❑ Seal joint located yV
olkscen‐ ot g
ua
trally at rear ed b ran
oris tee
❑ Renewing auth panel seal or
ac
⇒ page
ss 98
ce
e
nl
pt
3 - Sliding headlining
du
an
itte
y li

erm
ab
sliding headlining
ility
ot p
⇒ page 99 .
wit
, is n
h re
4 - Countersunk screws (mi‐

hole
spec
croencapsulated)
es, in part or in w
t to the co
❑ Always use new coun‐

tersunk screws
❑ 3.5 Nm
rrectness of i
5 - Slide
l purpos
6 - Upper trim
nf
ercia
or
m
m
atio
om
7 - Lower trim
n in
or c
thi
te
sd
iva
r
rp
cu
o
m
f
en
ng
8 - Water channel
t.
yi Co
op py
❑ Removed together with coulisse guide rail.
. C rig
ht ht
rig by
py
9 - Locking hook guide
co Vo
by lksw
cted agen
Prote AG.
10 - End piece
❑ To seal use butyl adhesive sealing cord -AKL 450 005 05- .
11 - Carrier unit
❑ Removing and installing carrier unit ⇒ page 102
❑ If necessary, guide channels should be lubricated only with special grease G 000 450 02, otherwise
function may be impaired.
3. Sliding/tilting sunroof with glass panel (Meritor) 93

Golf 1998 ➤
12 - Bolt
❑ 3.5 Nm
13 - Crank for emergency operation
❑ Clipped into cover of electric drive mechanism
14 - Electric drive
❑ Adjusting drive mechanism (0 position) ⇒ page 100
15 - Spring
16 - Wind deflector
17 - Torx screw
❑ Torx T25
❑ 4.5 Nm
18 - Rear guide
❑ Removed together with coulisse guide rail.
AG. Volkswagen AG d
agen
19 - Guide plate olksw
oes
not
byV gu
ara
❑ Removing ⇒ page 103 rised
nte
ho eo
ut
20 - Spacer ss a ra
c
❑ Installed together with coulisse guide rail
ce
le
un
pt
an
d
itte
21 - Bellows
y li
erm
ab
❑ From week 36/02
ility
ot p
wit
is n
h re
ole,
❑ Installing ⇒ page 96
spec
t to the co
Note
Bellows and trim should not be in‐
rrectne
terchanged. Clearance between
mechanical parts may otherwise be
impaired.
ss o
cial p
f inform
mer
3.2 Removing sliding/tilting sunroof glass

atio
m
panel
o
n
c
i
or
n thi
te
sd

iva
o
pr
cum
r
fo
– Tilt sunroof.
en
ng
t.
yi Co
Vehicles up to week 35/02 Cop py
ht. rig
rig ht
– Unclip lower trim -2- in front area towards centre of vehicle and py by
co Vo
by lksw
unhook at rear. Prote
cted AG.
agen

Golf 1998 ➤
– Disengage bellows -1- out of lower part of coulisse guide rail

-3-.
– Pull bellows -1- off securing pins -4-.
– Unhook bellows -1- at top rear -2-.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
– Remove securing screwsori(Torxse T25; 4.5 Nm). nte
eo
th
u ra
– Remove sliding/tiltingss asunroof panel upwards. c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
The sliding/tilting sunroof must not moved to “open” position when
wit
, is n
removed as the water channel will otherwise not be compressed
h re
hole
by the glass panel and could cant inside the roof.
spec
es, in part or in w
t to the co
rrectness of i
3.3 Installing glass panel for sliding/tilting
l purpos
sunroof
nf
ercia
Panel must be installed in 0 position (panel closed).
orm
m
3.3.1 Zero position: atio

om
n in
or c
The mark -arrow- on the rear of the guide upper section -1- must,
thi
te
sd
on both sides, lie within the marks dimension -a- on the guide
iva
o
r
plate -2-.
rp
cu
o
m
f
en
ng
t.
The guide plate -2- must be located in the guide rails (cannot be op
yi Co
moved by hand).
C py
t. rig
gh ht
yri by
If this is not the case, adjust parallel running ⇒ page 101 . cop Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
General body repairs, exterior - Edition
en AG. V08.2003
olkswagen AG
ag does
ksw not
y Vol gu
– Position sliding/tilting sunroof edpanel from above
b and screw in ara
nte
securing screws (coulisse oris
guide rail/panel). eo
th
au ra
c
– Lightly tighten securing s screws (Torx T25).
s
ce
le
un
pt
– Adjust sliding/tilting sunroof glass panel (height adjustment)
an
d
itte
y li
⇒ page 96 .
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
♦ After adjusting panel height, tighten securing screws (4.5 Nm).
es, in part or in w
t to the co
♦ On vehicles up to week 35/02, install upper and lower trim to
match panel height adjustment.
rrectness of i
l purpos

nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
do
r

rp
cum
fo
en
ng
♦ Install bellows after panel height adjustment.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
3.4 Adjusting glass panel for sliding/tilting
c by lksw
cted agen
Prote AG.
sunroof (height adjustment)
Note
The glass panel height adjustment is performed after the glass

panel has been closed from slide open position.
Zero position of sliding/tilting sunroof OK.

– Tilt sunroof.
– Unclip lower trim -2- in front area towards centre of vehicle and
unhook at rear.

Golf 1998 ➤
– Disengage bellows -1- out of lower part of coulisse guide rail

-3-.
– Pull bellows -1- off securing pins -4-.
– Unhook bellows -1- at top rear -2-.

– Loosen securing screws -3- (Torx T25; 4.5 Nm).
– Move panel to “open” position.
– Move glass panel to “closed” position.
– Carry out height adjustment of glass panel at front and rear on
both sides as follows:
AG. Volkswagen AG d
agen oes
olksw not
Panel adjustment front: d byV gu
ara
ise nte
r
-a- = 0…1 mm lower than ut roof
ho eo
ra
s a c
s
-Arrow- = Forwards
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
Panel adjustment rear:

rrectne
-b- = 0…1 mm higher than roof

ss
-Arrow- = Forwards
o
cial p
f inform
– Tighten screws for glass panel (4.5 Nm).

mer
atio
Always tighten left and right sides of glass panel symmetrically.

om
n
c
i
or
– Tilt sunroof.
thi
te
sd
va

i
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.

Golf 1998 ➤
– Hook in upper trim -1- at rear and clip front and centre in.
– Hook in lower trim -2- at rear and clip front in.
Note
♦ On vehicles from week 36/02, a bellows is installed in place of

the upper and lower trim.
– Hook in bellows -1- at top rear -2- first.

– Engage bellows -1- to securing pins -4-.
– Engage bellows -1- in lower part of coulisse guide rail -3-.
3.5 Adjusting panel seal

AG. Volkswagen AG d
agen oes
– Check that preload between panel seal -2- yV
oand
lksw body is uniform not
gu
all-round using a 0.3 mm thin strip ofiscard
ed b (e.g. business card). ara
nte
It must be possible to pull the papertho strip through between the
r eo
panel seal and body under load. ss
au ra
c
ce
e
– If the preload is insufficient, the panel seal can be spread apart

nl
pt
du
an
using a wedge -1-, or if the preload is excessive it can be

itte
y li
pushed together. To adjust the panel seal the glass panel -3-
erm
ab
must be removed.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.6 Renewing panel seal

rrectness of i

l purpos
– Pull seal -1- off glass panel.

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
o
by c lksw
cted agen
Prote AG.

Golf 1998 ➤
– Pull new seal on rear panel edge onto glass panel -2- centrally,
starting from bottom and rising to top.
Note
♦ To ease fitting of seal, apply soapy solution to edge of panel.

♦ If the seal is not correctly installed the surface will be undula‐
ted.
♦ The panel seal must be shortened to suit the panel circumfer‐
ence.
3.7 Removing wind deflector

– Open sliding/tilting sunroof completely.
– Insert special tool 3370 between edge of roof and wind de‐
flector mounting and release wind deflector side mountings
(left/right) by pulling special tool 3370.
– Lever wind deflector mounting out of guide rail (left/right) using
a screwdriver.
– Take out wind deflector.
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
3.8 Removing sliding headlining
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Remove front screws -arrow- on left and right-hand sides. Pull
t to the co
out slide forwards over the stop -1-.
– Move sliding panel forwards.
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
– Remove rear screws -arrow- on left and right-hand sides. Pull

ng
t.
yi Co
out slide to rear and remove sliding headlining -1-. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
3.9 Removing drive mechanism for sliding/

tilting sunroof
AG. Volkswagen AG d
agen oes
– Disconnect battery earth strap from battery. olksw not
byV gu
ara
ed
– Unclip cover -1- for drive mechanism. horis nte
eo
aut ra
ss c
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
Remove and install drive mechanism for sliding/tilting roof only
ility
ot p
with roof in closed (zero) position.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew screws -arrows- and pull off drive mechanism for
l purpos
The screws for the drive mechanism are microencapsulated and
nform
ercia
must always be renewed (3.5 Nm).

m
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
3.10 Adjusting drive mechanism for sliding/
agen
Prote AG.
tilting sunroof (zero position)

It may be necessary to adjust the zero position if the drive mech‐
anism was not removed in the zero position or the sliding/tilting
sunroof was closed or opened by means of the emergency de‐
vice.
Drive mechanism removed but still connected electrically.
– Select automatic “open sunroof” function on rotary switch.
– Select automatic “tilt roof” function on rotary switch.
– Install drive in this position (zero position) with sliding/tilting
sunroof closed.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Golf 1998 ➤
ris
ut
ho General e obody
ra
repairs, exterior - Edition 08.2003
s a c
s
3.11 Removing pre-selector control for slid‐
ce
e
nl
pt
du
an
ing/tilting sunroof
itte
y li
erm
ab
ility
ot p
– Unclip trim -1- in direction of arrow and remove.
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
io
– Remove screws -arrows- and remove pre-selector control.
n
c
in t
or
his
e

at
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.
3.12 Checking parallel running

The mark -arrow- on the rear of the guide upper section -1- must,
plate -2-.
The guide plate -2- must be located in the guide rails (cannot be
moved by hand).
3.13 Adjusting parallel running
Note
The parallel running adjustment can only be undertaken when the

drive and glass panel are removed (zero position).
– Removing sliding/tilting sunroof drive mechanism

⇒ page 100 .

olkswagen AG
wag en AG. V
Golf 1998 ➤ olks
does
not
yV gu
se
d b ara
nte
ri
ho eo
ut ra
The mark -arrow- on the rear of the guide -1- upper
ss section
a must, c
ce
le
un
pt
plate -2-.
an
d
itte
y li
The guide plate -2- must be located in the guide rails (cannot be
rm
ab
pe
ility
moved by hand).
ot
wit
, is n
– Slide guide upper part -1- from front to rear only centrally be‐
h re
hole
tween the markings.
spec
es, in part or in w
– Install drive mechanism in this (zero) position.
t to the co
Then check zero position.
rrectness of i
l purpos
3.14 Removing and installing carrier unit
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.
Removing
– Removing pre-selector control for sliding/tilting sunroof
⇒ page 101 .
– Remove moulded headliner ⇒ General body repairs, interior;
Rep. Gr. 70 ; Roof trim .
– Pull water drain hoses off carrier unit -1- -arrows-.

Golf 1998 ➤
– Remove bolts -2- and -4- (with sleeves) and lift carrier unit out
of vehicle with help of second mechanic.
Installing
– Insert carrier unit -1-, align to bolt holes and insert Vbolts -2- and
. olkswagen AG
-4- (with sleeves). swagen AG does
k not
y Vol gu
– Check correct routing of wiring and d bconnections from electrical ara
ise nte
consumers in roof and rectifyth as necessary.
or eo
au ra
c
– Tighten bolts (8 Nm) for carrier
ss unit -1-, starting at sliding/tilting
ce
e
sunroof drive mechanism -3- and moving backwards, alter‐
nl
pt
du
an
nating between left and right-hand sides.
itte
y li
erm
ab
– Fit water drain hoses -arrows-.
ility
ot p
wit
– Fit connector for drive mechanism -3-.
, is n
h re
hole
3.15 Removing coulisse guide rail
spec
es, in part or in w
t to the co
– Remove carrier unit ⇒ page 102 .
rrectness of i
– Removing sliding/tilting sunroof drive mechanism
l purpos
⇒ page 100 .
– Unclip end cap -1- from guide rail -2- as shown -arrows- and
nform
ercia
then pull off.

m
at
om
ion
Note
c
in t
or
his
ate
do
riv
When installing, bond end cap -1- to guide rail using Butyl adhe‐
p
cum
sive sealing cord -AKL 450 005 05- .
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unclip water channel -1- from locking lug guide -2- on both
sides carefully with a screwdriver and take off.
– Slide rear guide -1- in guide rail -4- in direction of arrow until
the locking lug guide -3- is released.
– Pull rear guide -1-, locking lug guide -3- and coulisse guide
-2- out of guide rail -4-.
Note
Always renew guide with cable as a pair.

Golf 1998 ➤
3.16 Cleaning water drain hoses
3.16.1 Front water drain hoses:
Note
recommended.
1 - Front water drain hoses

The front water drain hoses are
routed in the A-pillars and fin‐
ish between the door and A-
pillar. They are cleaned from
the sliding/tilting roof panel
aperture. AG. Volkswagen AG d
agen oes
olksw not
2 - Conduit d by V gu
ara
rise nte
tho eo
au 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
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
3.16.2 Rear water drain hoses:
Note
For cleaning, a locally manufactured tool

n AG. V made
olkswagen Afrom
G do
a speedometer inner cable, approx. 2300 mm long is
recommended. olks
wage es n
ot
yV gu
db ara
rise nte
tho eo
au ra
1 - Water drain
ss hose c
ce
le
un
The rear water drain hoses are
pt
an
d
routed in the C-pillars and fin‐

itte
y li
rm
ish behind the bumper cover
ab
pe
ility
beneath the rear light cluster.
ot
wit
They are cleaned from the bot‐
, is n
h re
tom hose end. To do this, the
hole
spec
bumper must be removed.
es, in part or in w
t to the co
2 - Conduit
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.

Golf 1998 ➤
63 – Bumpers
1 Front bumper
1.1 Assembly overview - bumper cover
Note
The removal and installation procedures may have to be modified slightly depending on variations in equipment.
1 - Bumper cover
❑ Material - PP/EPDM
2 - Bolt
❑ Qty. 7
❑ 6.6 Nm
3 - Guide element
❑ To remove and install,
pull out/push in bumper AG. Volkswagen AG d
cover parallel to guide lksw
agen oes
not
elements (left and right). d byV
o gu
ara
ise nte
r
4 - Wheel housing liner ut
ho eo
ra
s a c
5 - Bolt s
ce
le
un
pt
❑ Qty. 8
an
d
itte
y li
❑ 1.5 Nm
erm
ab
ility
ot p
6 - Speed nut
wit
is n
h re
❑ Qty. 8
ole,
spec
7 - Cover for headlight washer

system
t to the co
❑ The cover is clipped into
the washer jet of the
rrectne
headlight washer sys‐
tem ss
8 - Bumper strip
o
cial p
f i
❑ Clipped in bumper cover

nform
mer
❑ Bumper strip can only

atio
m
be unclipped with bump‐

o
n
c
er cover removed
i
or
n thi

te
sd
iva
o
pr
9 - Left air intake grille

um
r
fo
en
ng

t.
yi Co
Cop py
10 - Centre air intake grille ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
11 - Right air intake grille
106 Rep. Gr.63 - Bumpers

Golf 1998 ➤
1.2 Removing and installing bumper cover
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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
m
Removing
o
n in
or c
thi
– Separate release lever from bonnet lock ⇒ page 108 .

te
sd
iva
o
r

rp
cu
o
m
f
en
ng
– Pull covers -7- for headlight washer system off bumper cover
t.
yi Co
op
and unclip.
C py
t. rig
gh ht
yri by
– Loosen bumper cover -1- in area of wheel housing liner -4-.
op Vo
by c lksw
cted agen
Prote
– Unclip left air intake grille -9- and right air intake grille -11-.
AG.
– Unscrew bolts -2-.

– Pull bumper cover -1- off guide elements -3- (left and right).
– Separate temperature sensor connector.
Installing
1. Front bumper 107

Golf 1998 ➤
1.3 Removing release lever

– Swing securing clip -2- upwards.
– Open release lever -1- using a screwdriver -3- and pull off
bonnet lock.
– Pull release lever -1- with guide out from lock carrier.
1.4 Assembly overview - bumper carrier
1 - Bumper carrier
2 - Spreader nut AG. Volkswagen AG d
agen oes
❑ Qty. 3 olksw not
V gu
d by ara
e
3 - Bolt horis nte
eo
ut ra
❑ Qty. 3 ss a c
ce
le
❑ 1.5 Nm
un
pt
an
d
itte
4 - Guide element
y li
rm
ab
pe
ility
ot
pull out/push in bumper

wit
, is n
cover parallel to guide

h re
hole
elements (left and right)

spec
es, in part or in w
5 - Bolt
t to the co
❑ Qty. 4
❑ 8.5 Nm
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 1998 ➤
1.5 Assembly overview - bumper cover, Golf R32
Note
1 - Bumper cover
2 - Bolt
❑ Qty. 7
❑ 6.6 Nm
3 - Guide element
elements (left and right).
4 - Wheel housing liner
5 - Bolt
❑ Qty. 8
❑ 1.5 Nm
6 - Bolt
❑ Qty. 2 agen
AG. Volkswagen AG d
oes
lksw not
❑ 1.5 Nm d by
Vo gu
ara
ise nte
r
7 - Adapter ut
ho eo
ra
a
❑ With 2 speed nuts ss c
ce
le
un
❑ Before removing adapt‐

pt
an
d
er, remove wheel hous‐

itte
y li
erm
ing liner
ab
ility
ot p

wit
is n
⇒ page 111
h re
ole,
spec
8 - Speed nut
❑ Qty. 8
t to the co
9 - Cover for headlight washer

system
rrectne
❑ The cover is clipped into

the washer jet of the headlight washer system
ss o
10 - Left air intake grille

cial p
f inform

mer
atio
m
11 - Centre air intake grille

o
n
c
i
or
❑ Attached in bumper cover by clips

thi
te
sd
a
❑ Assembly overview ⇒ page 112

iv
o
pr
cum
r
❑ Removal of air intake grille is only possible with bumper cover removed
fo
en
ng
t.
yi Co
12 - Right air intake grille t. Cop py
rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Front bumper 109

Golf 1998 ➤
AG. Volkswagen AG d
agen oes
ksw
1.6 Removing and installing bumper cover, Golf R32
ol not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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 lksw
by
cted agen
Prote AG.
Removing
– Separate release lever from bonnet lock ⇒ page 108 .
– Pull covers -9- for headlight washer system off bumper cover
and unclip.
– Loosen bumper cover -1- in area of wheel housing liner -4-.
– Unclip left air intake grille -10- and right air intake grille -12-.
– Unscrew bolts -2-. Pull bumper cover -1- off guide elements
-3- (left and right).
– Separate temperature sensor connector.
Installing

Golf 1998 ➤
1.7 Removing and

wage
n AG.installing
Volkswagen AGadapter, Golf R32
doe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a 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
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.
Removing
– Remove front wheel housing liner ⇒ page 168 .
– Remove bumper cover, Golf R32 -1- ⇒ page 110 .
– Take off adapter -3-.
-4- speed nut
Installing
1. Front bumper 111

Golf 1998 ➤
1.8 Assembly overview - centre air intake and air guide, Golf R32
1 - Bumper cover
2 - Air guide
❑ Air guide can only be
taken out with bumper
cover removed
⇒ Item 1 (page 112) .
3 - Bolt
❑ Qty. 6
❑ 1.5 Nm
4 - Speed nut
❑ Qty. 6
5 - Clip
❑ Qty. 12
6 - Centre air intake grille
❑ Removal of air intake
grille is only possible
with bumper cover re‐
moved
❑ Removing:
– Removing bumper cov‐
er ⇒ Item 1 (page 112)
⇒ page 110 .
– Pull off clips -

⇒ Item 5 (page 112) .
AG. Volkswagen AG d
– Remove centre air in‐ ksw
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❑ Installing: ut
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Installation is carried out in the reverse order. When doing this, observe the following:
s
ce
le
un
pt
an
d
– Damaged clips ⇒ Item 5 (page 112) should be renewed.

itte
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erm
ab
ility
ot p
1.9 Assembly overview - bumper carrier,

wit
is n
h re
Golf R32
ole,
spec
⇒ “1.4 Assembly overview - bumper carrier”, page 108

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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Cop py
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112
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Rep. Gr.63 - Bumpers cted agen
Prote AG.
AG. Volkswagen AG d
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d byV gu
ara Golf 1998 ➤
e
horis General nte body
eo repairs, exterior - Edition 08.2003
aut ra
ss c
ce
le
2 Rear bumper
un
pt
an
d
itte
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ab
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ility
ot
2.1 Assembly overview - bumper cover
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
rrectness of i
l purpos
1 - Bumper cover
nform
ercia

m
a
com
ti
2 - Guide element
on in
r
te o
thi
s
iva
do
r

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cum
fo
en
ng
t.
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op
3 - Bolt
C py
ht. rig
rig ht
❑ Qty. 6 py by
co Vo
by lksw
cted
❑ 1.5 Nm
agen
Prote AG.
4 - Securing strip
5 - Bolt
❑ Qty. 4
❑ 6.6 Nm
6 - Bumper strip
❑ Clipped into cover
❑ Bumper strip can only
be unclipped with bump‐
er cover removed
⇒ page 114 .
7 - Bolt
❑ 6.6 Nm
❑ Only on Bora model
2. Rear bumper 113

Golf 1998 ➤
2.2 Removing and installing bumper cover
lkswage es n
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ir se tee
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ss
ce
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nl
pt
du
an
itte
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erm
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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
ercia
orm
m
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om
n in
or c
thi
te
sd
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Loosen bumper cover -1- in area of wheel housing liner (bolts
-3-).
– Remove tail lights ⇒ Electrical system; Rep. Gr. 94 ; Tail
lights .
– Separate connector (beneath left tail light) for number plate
light - Golf only.
– Unscrew bolts -5-. On Bora, also unscrew bolt -7-.
– Pull bumper cover -1- off guide elements -2- (left and right) and
securing strip -4-.
Installing

Golf 1998 ➤
2.3 Assembly overview - bumper carrier
Note
1 - Bumper carrier
2 - Bolt
❑ Qty. 4
❑ 1.5 Nm
3 - Securing strip
4 - Guide element
cover parallel to guide agen
AG. Volkswagen AG d
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ed ran
5 - Bolt horis tee
t or
❑ Qty. 5 au ac
ss
ce
❑ 1.5 Nm
le
un
pt
an
d
itte
6 - Spreader nut
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ab
❑ Qty. 5
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7 - Pop rivet nut

h re
ole,
❑ Qty. 2
spec
8 - Spreader nut t to the co
❑ Qty. 4
9 - Bolt
rrectne
❑ Qty. 2
s
❑ 6.6 Nm
s o
cial p
f i
10 - Bolt
nform
mer
❑ Qty. 4
atio
m
❑ 20 Nm
o
n
c
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te
sd
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fo
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t.
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Cop py
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Prote AG.
2. Rear bumper 115

Golf 1998 ➤
2.4 Assembly overview - towing bracket
1 - Towing bracket
❑ For vehicles with front
wheel drive
❑ For vehicles with 4Mo‐
tion
❑ Allocation ⇒ Genuine
Parts
⇒ page 117
2 - Bolt
❑ Qty. 4
❑ 60 Nm + 1/4 turn (90°)
further
❑ Always renew bolts after n AG. Volkswagen AG do
loosening lkswage es n
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3 - Socket o
ir se tee
th or
u
4 - Bolt ss
a ac
ce
e
❑ Qty. 3
nl
pt
du
an
itte
❑ 2.5 Nm
y li
erm
ab
ility
5 - Bumper cover
ot p
wit
, is n
h re
hole
spec
⇒ page 114
es, in part or in w
t to the co
6 - Ball hitch
❑ Removable
rrectness of i
– Removing and installing
l purpos
⇒ Operating instruc‐
tions
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
General
en AGbody
. Volksrepairs,
wagen AGexterior - Edition 08.2003
ag does
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y Vol gu
2.5 Removing and installing towing bracket
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
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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
r
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thi
s
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cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Removing
– Remove tow hitch -6- ⇒ Operating instructions .
– Remove rear wheel housing liner ⇒ page 169 .
– Removing bumper cover -5- ⇒ page 114 .
– Unscrew socket -3- from towing bracket -1-.
– Pull towing bracket -1- out of profile sections in bodywork.
Installing
Installation is carried out in the reverse order. When doing this,
observe the following:
– When installing towing bracket -1- use only new bolts -2-.
2. Rear bumper 117

Golf 1998 ➤
2.6 Assembly overview - bumper cover, Golf R32
Note
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ris
1 - Bumper cover tho eo
au ra
❑ Material - PP/EPDM ss c
ce
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un
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an
d
itte
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2 - Bolt
erm
ab
ility
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❑ Qty. 6
wit
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❑ 1.5 Nm
h re
ole,
spec
3 - Bolt
t to the co
❑ Qty. 4
❑ 6.6 Nm
rrectne
4 - Spreader rivet
❑ Qty. 2
ss
5 - Adapter
o
cial p
f in
❑ Removal of adapter is
form
mer
only possible with
atio
bumper cover removed
om
n
⇒ page 119
c
i
or
n thi
e

t
sd
va
⇒ page 120
i
o
pr
cum
r
fo
en
ng
6 - Bolt
t.
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op
❑ Qty. 2
C py
t. rig
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❑ 1.5 Nm p by
co Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
AG. Volkswagen AG d General body repairs, exterior - Edition 08.2003
agen oes
olksw not
V gu
by ara
2.7 Removing and installing bumper cover, Golf R32
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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
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
o
by c lksw
cted agen
Prote AG.
Removing
– Loosen bumper cover -1- in area of wheel housing liner (bolts
-2- and -6-).
– Remove tail lights ⇒ Electrical system; Rep. Gr. 94 ; Tail
lights .
– Separate connector (beneath left tail light) for number plate
light - Golf only.
– Remove spreader rivet -4-.
– Take off bumper cover -1-.
Installing
2. Rear bumper 119

Golf 1998 ➤
2.8 Removing and installing adapter, Golf R32
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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nl
pt
du
an
itte
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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
rrectness of i
l purpos
nform
ercia
Removing
m
at
om
ion
– Remove bumper cover, Golf R32 ⇒ page 119 .

c
in t
or
his
te

a
do
priv
cum
or
– Take off adapter -3-.

f
en
ng
t.
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Installing Cop py
t. rig
gh ht
yri
Installation is carried out in the reverse order. p by
co Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
2.9 Assembly overview - bumper carrier, R32
Note AG. Volkswagen AG d

agen oes
olksw not
The removal and installation
ed by procedures may have to be modified
V gu
ara slightly depending on variations in equipment.
ris nte
ho eo
aut ra
ss c
1 - Bumper carrier
ce
e
nl
pt
du
an
itte
2 - Securing strip
y li
erm
ab
ility
3 - Guide element
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4 - Bolt
❑ Qty. 3
rrectness of i
❑ 1.5 Nm
l purpos
5 - Spreader nut
❑ Qty. 3
nf
ercia
orm
6 - Pop rivet nut
m
atio
m
❑ Qty. 2
o
n in
or c
thi
e
7 - Bolt
t
sd
iva
o
r
❑ Qty. 2
rp
cu
o
m
f
en
ng
❑ 6.6 Nm
t.
yi Co
Cop py
8 - Spreader nut
t. rig
gh ht
yri by
❑ Qty. 4
op Vo
by c lksw
cted agen
Prote AG.
9 - Bolt
❑ Qty. 4
❑ 1.5 Nm
10 - Bolt
❑ Qty. 4
❑ 20 Nm
2. Rear bumper 121

Golf 1998 ➤
64 – Glazing
1 Flush bonded windows
AG. Volkswagen AG d
1.1 Tools Volksw
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not
by gu
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Special tools and workshopaut ra
c
equipment required ss
ce
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nl
pt
du
♦ Removal kit for flush bon‐
an
itte
y li
ded windows -
erm
ab
V.A.G 1474 A-
ility
ot p
wit
♦ Suction lifter -V.A.G 1344-
, is n
h re
hole
♦ Cutting tool -V.A.G 1351-
spec
es, in part or in w
♦ Windscreen removal kit -
t to the co
V.A.G 1755-
♦ Cartridge gun -V.A.G 1628-
rrectness of i
♦ Cartridge heater -
l purpos
V.A.G 1939-
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
122 Rep. Gr.64 - Glazing

Golf 1998 ➤
♦ Electric cutter -
V.A.G 1561 A-
♦ Cutter (58 mm) -V.A.G
1561/2-
♦ Cutter (U-shape) -V.A.G
1561/3-
♦ Scraper (25 mm) -V.A.G
1561/8-
♦ Cutter (offset) -V.A.G
1561/10-
♦ Double cartridge gun -
VAS 5237-
AG. Volkswagen AG d
agen oes
olksw not
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Flush bonded windows 123

Golf 1998 ➤
1.2 Materials
♦ 2K window adhesive -DA 004 600 A2- 3), 4)
♦ 1K window adhesive -DH 009 100 03- 5), 6)
♦ Activator -D 181 801 A1- 2)
♦ Glass primer/paint primer -D 009 200 02- 2)
♦ Cleaning solution -D 009 401 04- 2)
♦ Primer applicator -D 009 500 25- 2)
♦ Adhesive remover -D 002 000 10- 2)
♦ Cutting cord -357 853 999 A-
2) Materials are stored in the box D 004 700.
3) Observe curing time ⇒ page 142 .

4) Double cartridge gun -VAS 5237- must be used to apply these materials.
5) Heat, according to manufacturers instructions, using cartridge heater -
V.A.G 1939- .
6) Small cartridge 110 ml for sealing and/or when a 400 ml cartridge alone is not
sufficient.
1.3 Assembly overview - windscreen

en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
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ris
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c
ss
ce
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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
l purpos
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.

Golf 1998 ➤
1 - Windscreen
❑ Removing windscreen
⇒ page 127
❑ Installing windscreen
⇒ page 129
2 - PUR adhesive sealant
❑ Cross section of bead:
♦ Width = 7 mm
♦ Height = 11 mm (including
precoating, residual materi‐
al on window glass and win‐
dow flange)
❑ Curing time
⇒ page 142
3 - Gap -a- = 4 mm
4 - Sealing lip (component part
of precoating)
5 - Spacer lip (component part
of precoating)
6 - Roof moulding
7 - Door
8 - Windscreen adjuster
❑ 443 845 631 A
9 - PUR adhesive sealant joint
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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1.4 Removing and installing plenum cham‐
ut ra
s a c
s
ber cover
ce
e
nl
pt
du
an
itte
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erm
ab
ility
1.4.1 Removing
ot p
wit
, is n
h re
– Unbolt wiper arms (M8 hexagon nuts = 20 Nm).

hole
spec
– Pull off roof mouldings in area of A-pillars.

es, in part or in w
t to the co
– Pull off complete length of plenum chamber seal -1- and re‐
move bolts -2-.
rrectness of i
– Pull cover -3- of pollen filter out upwards towards the front.
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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125
c by lksw
cted agen
Prote AG. 1. Flush bonded windows
Golf 1998 ➤
Note
The plenum chamber cover must not be levered off with a tool
(screwdriver, wedge). The windscreen will be damaged and can
later crack.
– Lift up plenum chamber cover -1- at edge of windscreen.
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
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erm
ab
ility
– Now pull plenum chamber cover -1- out of mounting slot on
ot p
lower edge of windscreen beginning from edge of windscreen
wit
, is n
h re
-2- and at right angles.
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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
1.4.2 Installing
Note
Striking the plenum chamber cover can cause cracks in the wind‐
screen.
– Spray mounting slot -1- with soap solution to make it easier to

press the plenum chamber cover into it.
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
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rm
ab
– Press plenum chamber cover -1- in fitting slots, starting from

pe
ility
centre and moving in direction of arrow.

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
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
1.5 Removing windscreen
pyri by
Vo
co lksw
by
cted agen
Prote
– Remove A-pillar trim ⇒ General body repairs, interior; Rep.
AG.
Gr. 70 ; Pillar and side panel trim .

Golf 1998 ➤
– Release sun visor -1- from support -2-.

– Remove bolt -5-.
– Release sun visor mounting -4- from support and separate
connector -3-.
– Lever off cap -7-.
– Remove screws -8- and remove support -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Press interior rear-view mirror -1- downward at an angle
ce
le
un
pt
-arrow- off retaining plate (spring clip in mirror base).
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
– Lower middle sun visor -1- -arrow-.
cial p
f inform
– Remove self-tapping screw -2- from roof cross member -3-
mer
atio
and remove sun visor.
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.

Golf 1998 ➤
n AG. Volkswagen AG do General body repairs, exterior - Edition 08.2003
lkswage es n
o ot g
b yV ua
– Slide protective ed -1- -V.A.G 1474/8- between windscreen
ir sfoil
ran
o tee
and dash panel.
auth or
ac
ss
– Loosen sealing lip in upper area of windscreen using plastic
ce
le
un
pt
wedge and spray with cleaning solution -D 009 401 04- (as
an
d
itte
substitute for lubricant).
y li
erm
ab
ility
– Insert cutting cord -2- into window flange using tube .
ot p
wit
is n
– If gap is too small, guide cutting cord on outside and push un‐
h re
ole,
der lip with a plastic wedge.
spec
– Pull the end of the cutting cord through the adhesive seal ma‐
t to the co
terial into the vehicle interior with the awl (from -
V.A.G 1474 A- ).
rrectne
Note
ss o
cial p
f
Guide awl through adhesive sealing material as close as possible
inform
to body windscreen flange along sides of windscreen, to prevent
mer
damage to sealing lip.
atio
om
n
c
i
or
n thi
e
– Secure one end of the cord to the reel device -V.A.G 1654 A- .
t
sd
iva
o
pr
cum
r
– Pull second cord end into vehicle and counter hold with pulling
fo
en
ng
handle from -V.A.G 1351- .

t.
yi Co
Cop py
– Apply the reel device -V.A.G 1654- to “position I”.
t. rig
gh ht
pyri by
Vo
co
– Move reel device according to position required and cut win‐
by lksw
cted agen
dow free.
Prote AG.
– Use plastic wedge to press cutting cord against window glass

while cutting in order to have clearance at window flange and
dash panel.
1.6 Installing windscreen

Preparing old undamaged window for glazing ⇒ page 139 .
Preparing new window for glazing ⇒ page 139 .
Preparing body flange for glazing ⇒ page 141 .
Installation instructions ⇒ page 142 .
Curing time ⇒ page 142 .
1.7 Assembly overview - side window, Golf

Golf 1998 ➤
1 - Side window
❑ Removing side window
⇒ page 130
❑ Installing side window
⇒ page 131
2 - Ceramic coating
of precoating)
♦ Width = 7 mm
dow flange)
❑ Curing time
⇒ page 142
5 - Gap -a- = 5...6 mm
❑ The gap must be main‐
tained because the dis‐
tance is required to se‐
cure the roof load
system mountings.
AG. Volkswagen AG d
agen oes
olksw not
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ise nte
or eo
h
aut ra
ss c
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le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
1.8 Removing undamaged side window

– Remove side panel ⇒ General body repairs, interior; Rep. Gr.
rrectness of i
70 ; Pillar and side panel trim .

l purpos
– Remove B-pillar trim ⇒ General body repairs, interior; Rep.

Gr. 70 ; Pillar and side panel trim .
nform
ercia
– Remove side support for luggage compartment cover and re‐

move C-pillar trim ⇒ General body repairs, interior; Rep. Gr.
m
a
com
70 ; Pillar and side panel trim .

ion in
r
te o
– Insert plastic wedge between sealing lip and window flange.

thi
s
iva
do
r
– Release sealing lip from window flange and spray with clean‐
rp
cum
fo
ing solution -D 009 401 04- (as substitute for lubricant).

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 1998 ➤
– Pull cutting cord through the adhesive sealing material into in‐
side of vehicle using awl (from -V.A.G 1474- ).
– Guide cutting cord between sealing lip and window flange us‐
ing tube -1-.
– Place cutting cord around the side window.
– Install pulling handle from -V.A.G 1351- at outer end of cord

to counterhold.
– Attach cord end (inner) to reel device -V.A.G 1654 A- and cut
window free by operating winding device.
. Volkswagen AG
gen AG does
– Press cutting cord against window glass with plastic Vol
wedge
ksw
a
not
during cutting process, in order to have clearanceed
byat window gu
ara
flange. tho
ris nte
eo
au ra
c
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
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1.9 Removing damaged side window

h re
hole
spec
A damaged side window is removed in much the same way as a

es, in part or in w
damaged rear window ⇒ page 135 .

t to the co
1.10 Installing side window

rrectness of i
l purpos
Note
nf
The material used to pre-coat the side windows (2-door) has been
ercia
changed. Observe information on page ⇒ page 139 .

rm
m
atio
om
n in
c

or
thi
te
sd
a

iv
o
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f
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op
Installation instructions ⇒ page 142 . C py
ht. rig
rig ht
by
Curing time ⇒ page 142 . copy Vo
by lksw
cted agen
Prote
1.11 Assembly overview - side window, estate
AG.

Golf 1998 ➤
1 - Side window
❑ Removing side window
⇒ page 132
❑ Installing side window
⇒ page 133
❑ Side window has no pre-
coating
2 - Seal with spacing lip (part of
window)
♦ Width = 8 mm n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Height = 12 mm (including d byV ua
ran
residual material on win‐ ir se tee
ho
dow glass and window aut or
ac
flange) ss
ce
le
un
❑ Curing time
pt
an
d
itte
⇒ page 142
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ab
pe
4 - Locating pin
ility
ot
wit
, is n
❑ Qty. 2
h re
hole
❑ They locate the side
spec
window between rear
es, in part or in w
t to the co
door and rear lid
❑ If using old window this
is installed without locat‐
rrectness of i
ing pins
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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1.12 Removing undamaged side window

en
ng
t.
yi Co
Cop py
.
– Release luggage compartment trim in upper area ⇒ General
t rig
gh ht
yri by
body repairs, interior; Rep. Gr. 70 ; Pillar and side panel trim . cop Vo
by lksw
cted agen
Prote
– Remove C and D-pillar trim ⇒ General body repairs, interior;
AG.
Rep. Gr. 70 ; Pillar and side panel trim .

– Insert plastic wedge between sealing lip and window flange.
– Release sealing lip from window flange and spray with clean‐
ing solution -D 009 401 04- (as substitute for lubricant).
side of vehicle using awl (from -V.A.G 1474- ).

Golf 1998 ➤
– Guide cutting cord between seal and window flange using tube
-1-. gen AG
. Volkswagen AG
d wa oes
olks not
– Pull the other end of the dcord
by through into the interior and
V gu
ara
counterhold using handle
or
ise
-V.A.G 1351/1- . nte
eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Attach cord end to reel device -V.A.G 1654 A- and cut window
free by operating winding device.
– Press cutting cord against window glass with plastic wedge
rrectness of i
during cutting process, in order to have clearance at window
l purpos
flange.
– Two locating pins are attached to window in area of C-pillar.
nform
ercia
The locating pins are severed during the seal cutting proce‐
dure.
m
at
om
io
The window is reinstalled without locating pins as these are not
n
c
in t
r
available as a replacement part.

o
his
ate
do
priv
cum
for
en
ng
– One suction cup can be removed from the reel device, as

t.
yi Co
op
shown in illustration. This allows the spool of the reel device C py
t. rig
gh
to be positioned closer to the window flange.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.13 Removing damaged side window

A damaged side window is removed in much the same way as a
damaged rear window ⇒ page 135 .
1.14 Installing side window

Preparing new window without precoating for glazing
⇒ page 140 .
1.15 Assembly overview - rear window, Golf

Golf 1998 ➤
1 - Rear window
❑ Removing rear window
⇒ page 134
❑ Installing rear window
⇒ page 136
2 - Seal
❑ For rear window wiper
of precoating)
❑ Cross section of bead: AG. Volkswagen AG d
agen oes
lksw not
♦ Width = 7 mm by Vo gu
ara
d
ise nte
♦ Height = 11 mm utho(including
r eo
precoating, residual
ss a materi‐ ra
c
ce
e
nl
dow flange)
pt
du
an
itte
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❑ Curing time
erm
ab
⇒ page 142
ility
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wit
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5 - Trim panel
h re
hole
6 - Window heater contact
spec
es, in part or in w
t to the co
7 - Gap -a- = 4.5 mm
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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1.16 Removing undamaged rear window
Co
Cop py
t. rig
gh ht
yri
– Remove rear lid trim ⇒ General body repairs, interior; Rep. p by
co Vo
Gr. 70 ; Rear lid trim .
by lksw
cted agen
Prote AG.
– Pull off connections for heated rear window and press con‐
necting tabs onto window.
– Remove rear window wiper motor ⇒ Electrical system; Rep.
Gr. 92 ; Repairing rear window wash/wipe system .
– Remove additional brake light ⇒ Electrical system; Rep. Gr.
94 .
– Release sealing lip from window flange using plastic wedge
and spray with cleaning solution -D 009 401 04- (as substitute
for lubricant).

Golf 1998 ➤
– Guide trimming needle -2- with help of handle -1- under seal‐
ing lip -3- and puncture through adhesive bead (use side area
on edge of rear window).
Trimming needle must be guided as close as possible to the win‐
dow.
– Unscrew handle and feed cutting cord through eye of needle.
– Pull one end of cutting cord inside (use pliers and gloves).
– Guide cutting cord between sealing lip and window flange us‐
ing tube -1-.
AG. Volkswagen AG d
agen oes
olksw not
– Place cutting cord round rear window as shown. d by
V gu
ara
ise nte
or eo
h
aut ra
s c
Note s
ce
e
nl
pt
du
an
Press in cutting cord deep enough in order to avoid damaging the
itte
y li
erm
sealing lip and/or spacing lip.
ab
ility
ot p
wit
, is n
– Pull the other end of the cord through into the interior and
h re
counterhold using handle -V.A.G 1351/1- .
hole
spec
es, in part or in w
t to the co
– Mask window flange on inside -1- using nylon adhesive tape.

rrectness of i
– Secure end of cord on reel device.

l purpos
– Apply the reel device -V.A.G 1654- to “position I”.

nform
ercia

dow free.
m
at
om
ion

c
in t
or

his
ate
flange.
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
1.17 Removing damaged rear window
op Vo
by c lksw
cted agen
Prote AG.
– Protect body and interior against damage from glass splinters.
– Remove pieces of glass up to adhesive sealing material.
– Pull off connectors for rear window heating and aerial.

Golf 1998 ➤
– Cover flange -2- all round with textile reinforced adhesive tape.
– Cut through adhesive sealing material (with remainders of
glass) in window aperture using electric cutter and cutter -
V.A.G 1561/10- (with stop roller).
WARNING
Always wear protective goggles and leather gloves.
1.18 Installing rear window

AG. Volkswagen AG d
agen oes
Preparing new window for glazing ⇒ page 139 . Volksw not
gu
d by ara
e
Preparing body flange for glazing ⇒ page 141 . horis nte
eo
aut ra
Installation instructions ⇒ page 142 . ss c
ce
e
nl
pt
du
an
itte
y li
1.19 Assembly overview - rear window, Bora
erm
ab
ility
ot p
wit
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h re
1 - Rear window
hole
spec
❑ Removing rear window
es, in part or in w
t to the co
⇒ page 134
❑ Installing rear window
⇒ page 136
rrectness of i
2 - Gap -a- = 3 mm
l purpos

of precoating)
nform
ercia

m
at
om
ion
c
in t
or
♦ Width = 7 mm
his
ate
do
riv
p
cum
or

f
en
ng
t.
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Co
op py
dow flange) t. C rig
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❑ Curing time
op Vo
by c lksw
⇒ page 142 cted agen
Prote AG.
5 - Gap -b- = 6.5 mm

❑ Check gap using setting
gauge -3371-
6 - Windscreen adjuster
❑ 443 845 631 A
7 - Gap -c- = 3 mm

wage es n
yV
olks ot g Golf 1998 ➤
b ua
ir se
d General
ran
tee body repairs, exterior - Edition 08.2003
tho
u or
a ac
1.20 ss Removing undamaged rear window
ce
le
un
pt
an
– Pull off connections for heated rear window and press con‐
d
itte
y li
necting tabs onto window.
erm
ab
ility
ot p
– Remove rear shelf ⇒ General body repairs, interior; Rep. Gr.
wit
is n
70 ; Pillar and side panel trim; Removing and installing rear
h re
ole,
shelf .
spec
– Remove C-pillar upper trim ⇒ General body repairs, interior;
t to the co
Rep. Gr. 70 ; Pillar and side panel trim; Removing and instal‐
ling C-pillar upper trim (Bora) .
rrectne
– Release sealing lip from window flange using plastic wedge
and spray with cleaning solution -D 009 401 04- (as substitute
for lubricant).
ss o
cial p
f
– Place cutting cord in window flange with help of tube.
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
Press in cutting cord deep enough in order to avoid damaging the
sd
iva
o
sealing lip and/or spacing lip.
pr
cum
r
fo
en
ng
t.
yi Co
. Cop py
side of vehicle using awl (from -V.A.G 1474 A- ).
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull the other end of the cord through into the interior and
counterhold using handle -V.A.G 1351/1- .
– Secure inner end of cord on reel device.
– Position reel device -V.A.G 1654- .
– Insert protective foil -1- ( -V.A.G 1474/14- ) between rear win‐
dow and headliner.

dow free.
flange.

Golf 1998 ➤
– Instead of reel device -V.A.G 1654- , reel device -

V.A.G 1654 A- can be used.
– One suction cup can be removed from the reel device, as
shown in illustration. This allows the spool of the reel device
to be positioned closer to the window flange.
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
1.21 Removing damaged rear window
y li
rm
ab
pe
ility
– Protect body and interior against damage from glass splinters.
ot
wit
, is n
h re
– Remove pieces of glass up to adhesive sealing material.
hole
spec
– Pull off connectors for rear window heating and aerial.
es, in part or in w
t to the co
– Cover flange -2- all round with textile reinforced adhesive tape.
– Cut through adhesive sealing material (with remainders of
rrectness of i
glass) in window aperture using electric cutter and cutter -
V.A.G 1561/10- (with stop roller).
l purpos
WARNING
nform
mercia
a
Always wear protective goggles and leather gloves.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
1.22 Installing rear window Cop py
t. rig
gh ht
yri by
Preparing old undamaged window for glazing ⇒ page 139 . cop Vo
by lksw
cted agen
Prote AG.

Golf 1998 ➤
1.23 Preparinglkundamaged
swa
gen AG window
. Volkswagen AG
does for glaz‐
not
ing sed b Vo gu
y ara
ri n tee
ho
aut or
ac
ss
Note
ce
e
nl
pt
du
an
itte
♦ If installing an undamaged window, cut back residual adhesive
y li
erm
ab
seal to 1...2 mm, being careful not to damage primer and ce‐
ility
ot p
ramic coating.
wit
, is n
h re
♦ Remaining material serves as adhesion base for newly ap‐
hole
spec
plied adhesive sealing compound.
es, in part or in w
t to the co
WARNING
rrectness of i
Do not prime adhesion surface and do not treat with a cleaning
l purpos
solution. Keep adhesion surface free of dirt and grease.
nform
ercia
Exception: If bonding is not performed immediately after cutting

m
back, the remaining residual material must be activated with ac‐
at
om
io
tivator -D 181 801 A1- .
n
c
in t
or
his
ate
1.24 Preparing new window for glazing

do
priv
cum
for
en
g
New windows are supplied pre-coated with PUR. The pre-coating

n
t.
yi Co
op
comprise of items -1-, -2- and -3-. C py
t. rig
gh ht
yri
1- Sealing lip
p by
o Vo
by c lksw
cted agen
2- Spacing lip
Prote AG.
3- Area for application of adhesive bead

4- Window glass
1.24.1 Side window
Note
Due to the change in side window pre-coating material, the pre-

coating must be treated as follows:
– Cloth with silicon remover (part no. -LSE 020 100 A3- ).
– Clean area of application for adhesive bead -3- twice thor‐
oughly using cloth applied with solution.
– After a drying period of at least five minutes, activator -D 181
801 A1- should be applied in the normal way as per pre-coated
windows.
1.24.2 Gaps for side window

A gap of 5..6 mm between top edge of window and window flange
on side panel must be adhered to when fitting a side window.
Reason: This distance is required to fit the roof mounting system.
The rest of the adhesive sequence remains unchanged.

Golf 1998 ➤
1.25 Preparing new window without precoat‐

ing for glazing
For the 2-door Golf and Golf/Bora estate, a new window has been
introduced without pre-coating. Only the PUR sealing lip -1- and
the spacing lip -2- have been sprayed onto the new windows.
1- Sealing lip
2- Spacing lip n AG. Volkswagen AG do
lkswage es n
o ot g
3- Window glass d byV ua
ran
ir se tee
tho
u or
a ac
Note ss
ce
le
un
pt
an
d
The area to which the adhesive bead is applied -3- is not precoa‐
itte
y li
rm
ted or primed.
ab
pe
ility
ot
wit
, is n
– Clean a 20 mm wide strip all around edge of window using
h re
hole
cleaning solution -D 009 401 04- .
spec
es, in part or in w
– Then dry edge of window using a lint free cloth.
t to the co
WARNING
rrectness of i
Ceramic coating on window is not a primer! It must be primed
l purpos
before application of adhesive sealing compound! Use only

primer -D 009 200 02- !
nform
mercia
a
com
tio
– Now apply primer -2- using applicator -D 009 500 25- -1-
n in
r
te o
equally in one stroke.

thi
s
iva
do
♦ Drying time approx. 10 minutes

r
rp
cum
fo
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
To apply the sealing bead, the nozzle should be cut to shape so Prote
cted AG.
agen
that the sealing bead has a width of 8 mm and height of 12 mm.
1.25.1 All other windows

– Rub down precoating with a dry, lint-free cloth.
WARNING
Do not prime precoating and do not treat with cleaning agent.

Golf 1998 ➤
– Thinly apply activator -D 181 801 A1- using applicator -D 009

500 25- -1- (felt pad with holder) only to pre-coating -2- of win‐
dow.
– Allow activator to dry for at least 10 minutes.
Note
♦ Activator must not come into contact with paint or damage to

paintwork will ensue.
♦ Activator must not come into contact with the window heater
bus bar.
1.26 Preparing body flange for glazing

– Cut back remaining material on window flange using scraper
-V.A.G 1561/8- , but do not remove completely.
Note
Remaining material serves as adhesion base for newlyGapplied

Volkswagen AG
adhesive sealing compound. Keep dirt and grease en Aof .bonding
wagoff does
ks
surfaces. l not
Vo gu
by a
ed ran
ris tee
tho or
au ac
WARNING ss
ce
e
nl
pt
du
an
Activator must not come into contact with paint or damage to
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Exception: if bonding is not performed immediately after cutting
hole
spec
es, in part or in w
tivator -D 181 801 A1- .

t to the co
Note
rrectness of i
l purpos
If the window flange has been repaired or partially renewed, after

painting, the area concerned must be cleaned and primed again.
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.

olkswagen AG
en AG. V
Golf 1998 ➤ ksw
ag does
not
Vol
General body repairs, exterior - Edition 08.2003ed by gu
ara
ris nte
utho eo
ra
1.27 Installation instructions ss
a c
ce
le
un
pt
– Apply adhesive material (continuous bead) to pre-coating -1-
an
d
itte
at right angle to window.
y li
rm
ab
pe
ility
ot
wit
WARNING
, is n
h re
hole
spec
Window must be installed within 10 minutes, or adhesive prop‐
es, in part or in w
erties of window adhesive will be impaired.
t to the co
♦ With help of two double suction cups ( -V.A.G 1344- ) install
rrectness of i
glass pane in window aperture, align to centre and press in
l purpos
onto the spacing lip.
♦ Windscreen gap/shut line ⇒ page 124 .
nform
ercia
♦ Secure windscreen during curing time with window adjusters

m
(443 845 631 A).
a
com
tion in
♦ It is essential to install the plenum chamber cover as described
r
te o
thi
on page ⇒ page 125 .
s
iva
do
r
rp
c
♦ Replace stickers (e.g. for airbag) which may be installed.
um
fo
en
ng
t.
yi Co
op
– When installing, place mirror -1- in position at 60...90° and turn
C py
t. rig
gh
-arrow- until locking spring clicks into place.
ht
pyri by
Vo
co lksw
by
♦ Insert seal for rear window wiper motor drive shaft into rear cted agen
Prote AG.
window.
♦ On Bora models, check gap/shutline using setting gauge
-3371- between rear lid and rear window; Rear window gaps/
shutlines ⇒ page 136 .
♦ Rear window gaps/shutlines ⇒ page 133 .
♦ The activator must not come into contact with the window
heater bus bar.
♦ Use adhesive tape to secure rear window in position while
curing.
♦ Secure rear window during curing time using window adjusters
(443 845 631 A).
♦ If the adhesive bead is applied too thick and the adhesive ex‐
pands onto the area of the window heating, excess adhesive
must be removed.
1.28 Minimum curing time
WARNING
Special standards must be adhered to when replacing bonded

windows. 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
time.
A shorter curing time has been made possible by the introduction

of the new 2 pack adhesive -DA 004 600 A2- .
Window Vehicle Window adhesive Minimum
curing time
Windscreen With and DA 004 600 A2 3 hours
without air‐
bag

AG. Volkswagen AG d Golf 1998 ➤
agen
Volksw General
oes
not body repairs, exterior - Edition 08.2003
by gu
d ara
ise nte
r
Window Vehicle
ut
ho
Window adhesive Minimum eo
ra
ss a
curing time c
ce
le
Side windows
un
pt
an
d
and rear win‐ itte
y li
rm
dows
ab
pe
ility
ot
wit
The minimum curing time is the period between bonding the ac‐
, is n
h re
cessory parts to installation. During this time, the vehicle must be
hole
parked on a hard level standing at room temperature (at least15°
spec
es, in part or in w
C).
t to the co
WARNING
rrectness of i
Vehicle is only safe to use after curing time has elapsed.
l purpos
nform
ercia
1.29 Touching up paint damage

m
a
Paint structure must be restored according to specifications in the
com
tion in
“Paint” workshop manual.
r
te o
thi
s
The following repair method is suitable for paint finish damaged
iva
do
r
in areas which are not visible:

rp
cum
fo
en
ng
– Painting over twice (wet-on-wet) with glass/paint primer -D

t.
yi Co
op
009 200 02- - flash-off time = at least 10 minutes.
C py
t. rig
gh ht
yri by
1.30 Cleaning off excess adhesive sealing
op Vo
by c lksw
cted agen
Prote
material
AG.
– Use of adhesive remover -D 002 000 10- as a cleaning solution

is recommended. Observe the appropriate safety precautions
when performing this work.
WARNING
Glass which has just been installed should not be pressed out‐
wards whilst cleaning from inside of vehicle.
– First clean painted surface as much as possible using a dry

cloth. Remove residue using adhesive remover -D 002 000
10- .
– Cleaning plastic trim: Allow adhesive sealing material to cure
(approx. one hour) and then peel off.

Golf 1998 ➤
wageexterior - Edition 08.2003
e
ks s no
Vol t gu
d by ara
e nte
ris
2 Door window
autho eo
ra
c
ss
ce
le
un
pt
an
d
2.1 Tools
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
equipment required
spec
t to the co
rrectne
s
-3320-
s o
cial p
f i
nform
-3320-
mer
atio
m
♦ Socket -3410-
o
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.

Golf 1998 ➤
2.2 Assembly overview - front door window
1 - Window channel
2 - Door
3 - Inner window aperture seal
4 - Bolt
❑ 20 Nm
5 - Assembly carrier
⇒ page 146
❑ Window regulator is part
of assembly carrier
6 - Window regulator motor
❑ Bolted to front of assem‐
bly carrier
❑ Torque setting for win‐
dow regulator motor
bolts: 3.5 Nm
7 - Bolt
❑ Plastic clamping jaws 9
Nm
❑ Aluminium clamping
jaws 11 Nm
AG. Volkswagen AG d
8 - Cap lksw
agen oes
not
Vo gu
y
9 - Bolt rise
d b ara
nte
o eo
❑ 8 Nm auth
ra
ss c
10 - Crank drive for mechanical
ce
e
nl
pt
window regulator
du
an
itte
y li

erm
ab
bly carrier
ility
ot p
wit
, is n
11 - Door window
h re
hole

spec
es, in part or in w

t to the co
rrectness of i
2.3 Removing front door window

l purpos

Rep. Gr. 70 ; Door trim .
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.
2. Door window 145

Golf 1998 ➤

– Lower door window until clamp securing bolts are accessible
on clamping jaws.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Lift rear of door window and take out of door forwards,
orise in di‐ nte
eo
rection of arrow. auth
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
2.4 Adjusting door window
l purpos
– The door window clamping jaws must be positioned in the as‐

sembly opening.
nf
ercia
– Slide door window -3- without additional force in clamping jaws orm
m
atio
m
and align to rear window channel -arrow-.

o
n in
or c
– When doing this, ensure that window is parallel to window

thi
te
sd
a
channel.
iv
o
r
rp
cu
o
– Tighten clamping jaws by means of bolts -4- (9 Nm).

f
en
ng
t.
yi Co
op
• Then perform functional check. C py
t. rig
gh ht
yri by
Items 1 and 2 in the diagram are of no significance. cop Vo
by lksw
cted agen
Prote AG.
2.5 Removing and installing assembly car‐

rier
and loudspeaker.
The window regulator is supplied with the assembly carrier.

Golf 1998 ➤
The assembly carrier can only be removed if the door window is

unbolted from the clamping brackets of the window regulator. To
do this, lower door window to the height of the assembly holes in
assembly carrier and loosen clamping brackets.
diagnosis; Rep. Gr. 01 ; Interrogating fault memory .
If an electrical fault hasabeen
n AGcaused
. Volkswagby the
en AG dowindow regulator
w ge
motor, the motor canVo be removed from the assembly
lks es n
ot g carrier.
by ua
ed ran
2.5.1 thoRemoving
ris tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Lower door window until securing bolts for door window are
hole
spec
accessible.
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nf
ercia
orm
– Slide door window upwards and hold in place (e.g. with adhe‐
m
atio
m
sive tape).
o
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
– Separate all wiring connectors -arrows-.
by lksw
cted agen
Prote AG.
2. Door window 147

Golf 1998 ➤
– Remove screws -2-.

. Volkswage
– Remove bolts -arrows-. Pullksassembly
wage
n AG carrier at topooff
n AG d
es ndoor,
raise and lift out of doorbytoV hinge side of door.
ol ot g
ua d ran
ise
– Turn assembly carrier
ut
ho
r
and pull connector off door lock. tee
or
sa ac
– Then disengage
s clips for electrical wiring on back of assembly
ce
le
carrier.
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
2.5.2 Installing assembly carrier

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.

Golf 1998 ➤
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
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.

to the spring.
Note
2. Door window 149

Golf 1998 ➤
fied.
– Insert door window -3- through window aperture without addi‐
tional force in clamping jaws and align to rear window channel
-arrow-.
– When doing this, ensure that window is parallel to window
channel.
– Tighten clamping jaws by means of bolts -4-.
• Torque setting: Plastic clamping jaws 9 Nm, aluminium clamp‐
ing jaws 11 Nm.
al.
2.6 Assembly overview - rear door window
1 - Door
2 - Bolt
3 - Outer window channel
4 - Quarter light window
⇒ “2.7 Removing and in‐
stalling assembly carri‐ n AG. Volkswagen AG do
lkswage es n
er, rear door window byV
o ot g
ua
and quarter light win‐orised ran
tee
dow”, page 151 au th or
a
ss c
5 - Bolt
ce
e
nl
pt
du
❑ 10 Nm
an
itte
y li
erm
ab
6 - Cap
ility
ot p
wit
7 - Bolt
, is n
h re
hole
8 - Middle frame
spec
es, in part or in w
9 - Assembly carrier
t to the co

⇒ page 151
rrectness of i
❑ Window regulator is part

of assembly carrier
l purpos

nform
ercia

bly carrier
m
at
om
❑ Torque setting for win‐

on
c
in t
dow regulator motor

or
his
e
bolts: 3.5 Nm
at
do
priv
11 - Crank drive for mechanical

um
for
en
g
window regulator
n
t.
yi Co
op
C py
t. rig
gh
bly carrier
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
12 - Inner window aperture seal

13 - Bolt
❑ 8 Nm
14 - Door window
15 - Window channel
❑ Engaged in filler piece
16 - Filler piece
2.7 Removing and installing assembly agen

AG. Volkcar‐
swagen AG
does
rier, rear door window db
yand
Volksw
quarter light not
gu
ara
window ise nte
or eo
th
au ra
c
The following instructions “Removing
ss assembly carrier” include
ce
e
the door window and the quarter light window.

nl
pt
du
an
itte
y li
erm
ab
and loudspeaker.
ility
ot p
wit
The window regulator is included in the items supplied with the
, is n
h re
assembly carrier and cannot be ordered separately.
hole
spec
The assembly carrier, however, can only be removed if the door
es, in part or in w
t to the co
window is released from the window regulator. To do this, lower
window to height of installation hole in assembly carrier and re‐
move spreader pins.
rrectness of i
l purpos

nform
ercia

diagnosis; Rep. Gr. 01 ; Interrogating fault memory .
m
at
om
io

n
c
in t
r

o
his
ate
do
riv
2.7.1 Removing
p
cum
for
en
ng
t.
– Removing rear door trim ⇒ General body repairs, interior;
yi Co
op
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
2. Door window 151

Golf 1998 ➤
General body repairs, exterior - Edition
en AG. V08.2003
olkswagen AG
ag does
ksw not
y Vol gu
– Lever out cap -1-. d b ara
rise nte
ho eo
– Lower door window until a spreader pin -2- and spreader plug
ut ra
c
-3- are accessible in the
ss
cut-out of the window regulator.
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Screw a 5 mm bolt (approx. 70 mm long) in the spreader pin
t to the co
-2- and pull out from spreader plug -3-.
– Now screw an 8 mm bolt (approx. 80 mm long) into spreader
rrectne
plug -3-.
ss o
Note
cial p
f inform
mer
When screwing in bolt, do not exert too great a pressure on the
atio
m
spreader plug because otherwise the plug will fall into the door.
o
n
c
i
or
n thi
te
sd
– Pull spreader plug out of window guide and thereby out of door
iva
o
r
window.
p
cum
r
fo
en
ng
t.
– When doing this press window regulator Bowden cable to side op
yi Co
with a screwdriver.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Pull off seal -1- from centre column to window aperture seal Prote
cted AG.
agen
-2-.
– Then remove screw that becomes visible.

Golf 1998 ➤
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
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
o
by c lksw
cted agen
Prote AG.
– Using a screwdriver -1-, lift up locking lug -2- and take filler
piece -3- upwards out of window column.
– Grasp inner window aperture seal -1- using pliers -2-. Then
move pliers in direction of arrow whilst lifting the window aper‐
ture seal -1- up out of door flange with light twisting motion at
the same time.
– To ease removal of the window aperture seal, use a wedge
-3- to supplement the pliers.
2. Door window 153

Golf 1998 ➤
– Slide door window -1- upwards and take out of door towards
interior -arrow-.
– Pull off window guide -1- in upper area and remove cross-head
-2- in centre column. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
Note oris eo
th
au ra
c
ss
♦ The cross-head screw -2- will gradually be discontinued. In‐
ce
e
nl
pt
stead, the centre column will be clipped in at the top of the
du
an
itte
door.
y li
erm
ab
♦ The remaining work sequence is the same. ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove hexagon bolt -1-.

– Pull centre column -2- off quarter light window seal -3- and pull
downwards out of upper window guide.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
– Take centre column -1- upwards out of door.

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

Golf 1998 ➤
2.7.2 Continuation for removal of quarter light

window
. Volkswagen AG
wa gen AG d
– Pull window channel V-1- olksoff door flange -2-. Turn lower
oes
not area of
gu
window channel eoutwards
db
y by 90° -arrow A- and then pullara off
nte
window aperture
thoris
seal -3- upwards -arrow B-. eo
au ra
c
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
– The quarter light window can now be removed in an arch
rrectne
-arrow- out of the door.
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
t. rig
gh
2.7.3 Continuation for removal of assembly
ht
pyri by
Vo
co lksw
by
carrier cted agen
Prote AG.
– Remove bellows -1- from B-pillar.

– Separate connector -2-.
2. Door window 155

Golf 1998 ➤
– Remove bolts -arrows-.

– Unscrew bolts -1- (for lock).
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
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull assembly carrier off door from above, lift up and lever out
l purpos
of door towards hinge side -arrow- of door.

– The release the two clips for the wiring off the reinforcement
nform
ercia
panel in the door and pull wire out of rubber boot.

m
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.
2.7.4 Installing quarter light window

– Insert quarter light window in door -arrow A- (use a soap sol‐
ution to aid installation).
– Position window channel -1- from outside on door flange -2-
and turn outwards by 90°.
– Then insert window channel - as shown in the diagram - in the
window aperture.
– The window aperture seal -3- can now be pressure down‐
wards -arrow B- onto the door flange.
– Position window channel -1- in the door flange -2- and install
completely.
al.

Golf 1998 ➤
2.7.5 Installing assembly carrier
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
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 Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

to the spring.
Note
– Guide wire through rubber boot in door and secure clips in door
panel.
2. Door window 157

Golf 1998 ➤
fied.
– Install door window. To do this, see instructions on how to in‐
stall door window to window regulator ⇒ page 158 .
al.
2.8 Fitting door window to window regulator

– Before renewing spreader plug and spreader pin, check glass
for damage.
Note
When installing door window, always renew spreader plug and

spreader pin.(part no. -6N0 839 511- ).
G. Volkswagen AG d
– Insert spreader plug -2- in centre position withlkwindow
wage
n A re‐ oes
moved. Vo s not
gu
by d ara
r ise nte
– Push spreader pin -1- flush into spreader
ut
ho plug -2-. eo
ra
a c
– Guide window into door. ss
ce
le
un
pt
– Insert door window -3- in the window lifting rail guide slot -4-.
an
d
itte
y li
rm
ab
– By applying slight pressure from above, engage glass in win‐

pe
ility
dow regulator -arrow-.

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
2.9 Electric window regulator with conven‐

com
tion in
ience function (automatic opening and

r
te o
thi
s
iva
closing) and force limitation mechanism

do
r
rp
cum
fo
With the introduction of the convenience power windows, the win‐

en
ng
t.
yi Co
dow regulators are also equipped with automatic opening and Cop py
closing features. ht. rig
rig ht
py by
co Vo
The switch for the front window automatic opening and closing
by lksw
cted agen
functions is located in the driver's door controls. The switch for
Prote AG.

Golf 1998 ➤
the driver's and front passenger's door is equipped with a two

level function.
If the relevant switch is pushed or pulled to the first detent position,
the front window is opened or closed manually.
If the switch is pressed or pulled to the 2nd detent position briefly,
the front windows will open or close automatically.
There are also additional switches in the front passenger's door
and the rear doors for individual window regulation.
All power windows are equipped with a force limitation mecha‐
nism. If when the window is closing its path is blocked, the window
will stop automatically.
However, the force limitation mechanism does not work if the
windows are closed from outside the vehicle with the ignition key.
2.9.1 Function of window regulator with igni‐

tion switched on
Opening
Switch in driver's door
• Front windows:
– Press front section of switch down to 1st detent. The window
will be opened manually.
– Press front of switch down briefly to 2nd detent. The window
will be opened automatically (automatic fully opening system).
– If the switch is operated again the window will stop immedi‐
ately.
• Rear windows:
– Press front section of switch down. The window will be opened
manually.
. Volkswagen AG
gen AG does
Switches in front passenger's doorVand
olks rear doors
wa not
y gu
db ara
– Press lower part of switch. orisThe window will be opened man‐
e nte
ually. aut
h eo
ra
ss c
Closing
ce
le
un
pt
an
d
Switch in driver's door

itte
y li
rm
ab
• Front windows:
pe
ility
ot
wit
, is n
– Pull front section of switch up to first detent. The window will

h re
be closed manually.
hole
spec
es, in part or in w
– Pull front section of switch briefly up to 2nd detent. The window

t to the co
will be closed automatically (automatic fully closing system).

– If the switch is operated again the window will stop immedi‐
rrectness of i
ately.
l purpos
• Rear windows:
– Pull front section of switch up. The window will be closed man‐
nform
ercia
ually.
m
Switches in front passenger's door and rear doors

a
com
tion in
– Press upper part of switch. The window will be closed man‐

r
te o
thi
ually.
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.
2. Door window 159

Golf 1998 ➤
2.9.2 Function of window regulator with igni‐

tion switched off
The window regulators can be operated for approx. 10 minutes
after switching ignition off, as long as the driver's or front pas‐
senger's door have not been opened.
When closing the front windows there is no automatic closing
function.
If the window in the driver's or front passenger's door is impeded
because it is tight or encounters an object during the closing se‐
quence (force limitation) the window will open immediately.
In this case the window can only be closed again if the ignition is
switched on.
The windows can be opened and closed from the exterior on ve‐
hicles with a central locking system. The key must be held in the
lock or unlock position.
2.9.3 Setting automatic opening and closing
Note
The automatic opening and closing features for the driver's and
front passenger's windows do not function after disconnecting
and reconnecting the vehicle battery.
To reinstate this feature after reconnecting the vehicle battery

proceed as follows:
– Lock vehicle from outside using driver's or front passenger's
door.
When doing this, ensure that all doors and windows are closed
completely.
– Unlock vehicle and lock vehicle again at driver's or front pas‐
senger's door. When doing this hold the key for at least one swa
gen AG
. Volkswagen AG
does
second in the lock position. by
Volk not
gu
ara
ed nte
The automatic opening and closing functions for the driver's ris
tho and e or
front passenger's window is reactivated. s au ac
s
ce
le
If there is a fault with the power windows, this will be indicated by

un
pt
a flashing switch light in the driver's and front passenger's door

an
d
itte
y li
and in the rear doors.

rm
ab
pe
ility
All lights in the door trim will flash for approx. 15 seconds after
ot
wit
, is n
switching on the ignition.

h re
hole
spec
2.10 Overriding resistance in event of force

es, in part or in w
t to the co
limitation intervention
• Prerequisite: Automatic fully opening and closing system OK
rrectness of i
• Ignition switched on.

l purpos
– Close door window with window regulator switch (automatic

closing).
nform
ercia

m
because it is tight or it encounters an object during the closing

a
com
tio
sequence (force limitation intervention) the window will open im‐

n in
r
mediately.
te o
thi
s
iva
do
– After the window has opened the relevant window switch must
r
rp
cum
be lifted or pressed and held within 5 seconds.

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
160
co Vo
by lksw
cted
Rep. Gr.64 - Glazing
agen
Prote AG.
Golf 1998 ➤
If the window is impeded again because it is tight or it encounters

an object, the window will stop immediately (force limitation inter‐
vention).
– After the window has stopped the switch must be operated
within 5 seconds again to close the window.
The window will now close without force limitation intervention
beyond the obstruction.
• Ignition switched off.
because it is tight or it encounters an object during the closing
sequence (force limitation intervention) the window will open im‐
mediately.
Operation via the interior window regulator switch is now blocked.
If, within one minute of opening the window, the ignition is switch‐
ed on and the switch pressed to close the window, the window
will close without automatic closing.
2.11 Removing and installing window regula‐

tor motor or assembly carrier with win‐
dow regulator
2.11.1 Removing
The illustration shows removal and installation of window regula‐
tor motor/assembly carrier with window regulator on the rear
doors. The removal and installation procedure is the same on the
front doors. gen AG
. Volkswagen AG
d wa oes
olks not
Removing assembly carrier at front/rear ⇒ page d146
by or
V gu
ara
⇒ page 151 . orise nte
eo
h
ut ra
– Slide a hammer shaft between the window
ss
a
guide and the as‐ c
sembly carrier until the end of the hammer shaft presses
ce
le
un
against the assembly carrier. pt

an
d
itte
y li
erm
– Remove screws -1- and take off window regulator motor. ab

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
2.11.2 Installing window regulator motor

s o
cial p
f in
– The mechanism will change position when the window regu‐

form
mer
lator motor is removed, it is then no longer aligned.

atio
om
– The mechanism must be aligned to the central position when

n
c
i
or
the window regulator motor is installed.

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Door window 161

Golf 1998 ➤
– Insert bolts -1- and tighten.

Torque setting: 3.5 Nm
The torque setting must be strictly adhered to, otherwise the plas‐
tic sleeve on the window regulator could become damaged.
2.11.3 Installing assembly carrier with window

regulator
On a replacement assembly carrier the mechanism is secured
with a cable tie -1- to prevent it moving or falling out.
– Slide a hammer shaft between the window guide and the as‐
sembly carrier until the end of the hammer shaft presses
against the assembly carrier.
– Remove cable tie -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
– The mechanism will change
ss a position when the window regu‐ c
lator motor is removed, it is then no longer aligned.
ce
e
nl
pt
du
an
– The mechanism must be aligned to the central position when

itte
y li
erm
the window regulator motor is installed.

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
– Insert bolts -1- and tighten.

Torque setting: 3.5 Nm
nform
ercia
The torque setting must be strictly adhered to, otherwise the plas‐
m
at
om
tic sleeve on the window regulator could become damaged.

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.
2.12 Assembly overview - assembly carrier with window regulator

agen
AG. Volkswagen AG d
oes
Golf 1998 ➤
ksw
gu General body repairs, exterior - Edition 08.2003
ol not
byV ara
ed
ris nte
1- Assembly
aut
ho
carrier eo
ra
ss c
2 - Clamping jaws
ce
e
nl
pt
du
an
3 - Carrier
itte
y li
erm
ab
ility
ot p
wit
❑ For electric window reg‐
, is n
h re
ulator
hole
spec
5 - Crank
es, in part or in w
t to the co
❑ For mechanical window
regulator
rrectness of i
6 - Bowden cable, long
❑ Cable reel - rear carrier
l purpos
7 - Guide roller
nf
ercia
❑ With eccentric
orm
❑ Without eccentric
m
atio
om
n in
8 - Guide rail
or c
thi
te
sd
9 - Diagonal Bowden cable
iva
o
r
rp
cu
10 - Cable reel
o
m
f
en
ng
t.
yi Co
11 - Bowden cable, short Cop py
ht. rig
❑ Cable reel - front carrier
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.13 Repairing window regulator

For repairs to the window regulator, the following components can
be replaced:
♦ Carrier with clamping jaws
♦ Cable reel with Bowden cable
♦ Window regulator motor (for electric window regulator)
♦ Crank (for mechanical window regulator)
2.13.1 Removing
– Removing assembly carrier with window regulator
⇒ page 146 .
Vehicles with electric window regulators
– Removing window regulator motor ⇒ page 161 .
Vehicles with mechanical window regulators
– Removing crank and relay element for cable reel
⇒ page 164 .
2. Door window 163

Golf 1998 ➤
Note
♦ Repairs to window regulators using the repair set is only pos‐

sible if these are equipped with eccentric guide rollers -1-.
♦ For window regulators with guide rollers that do not have an
eccentric cam -2-, the complete assembly carrier must be re‐
newed.
♦ The colour of the guide roller is of no significance.
♦ Protect loudspeakers against damage during complete repair
procedure.
♦ Place assembly carrier on levelagsurface.
en AG. V Support
olkswagen Aif
G necessary.
do
w es n
olks ot g
byV ua
– Check guide rollers,risguide
ed rails and seals for damage. In therante
o
event of damage,authrenew assembly carrier. eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Locate start and finish of diagonal Bowden cable -4-. Do not
ility
ot p
damage diagonal Bowden cable -4-. This is not meant to be
wit
, is n
replaced.
h re
hole
– Separate Bowden cables -2- and -6-, located at cable reel

spec
es, in part or in w
-5-, in position of guide rails -3- and -7-.

– Slide carrier and clamping jaws -1- on guide rails to uppermost t to the co
position. Carrier with clamping jaws can only be removed in
this position.
rrectness of i
l purpos
nform
mercia
at
– Fold up carrier and clamping jaws -1- in -direction of arrow-.

om
ion
When doing this, note position of Bowden cables -2- and -3-
c
in t
or
in the carrier.
his
ate
do
riv
– Remove separated ends of Bowden cables out of carriers.

p
cum
for
en
ng
– The diagonal Bowden cable position should not be altered.

t.
yi Co
Cop py
.
Remove crank (vehicles with mechanical window regulator)
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull off crank -2-.

Golf 1998 ➤
– Remove seals -2-.

– Pull off relay element for cable reel -1-.
– Press together retaining clips of threaded sleeves -arrows-.

– Remove cable reel from assembly carrier.
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
– Clean guide rails -1- and -2- and opening -arrow- of grease
an
itte
y li
and dirt.
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
2.13.2 Installing
m
at
om
io
– Insert threaded sleeves -arrows- for new cable reel through

n
c
in t
r
opening in assembly carrier.

o
his
ate
do
riv
– Separate cable ties on cable reel and remove.

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Door window 165

Golf 1998 ➤
. Volkswagen AG
a gen AG does
– Engage cable reel -1- in assembly carrier by applying
Vol light
ksw not
gu
pressure. ed
by ara
nte
ris
utho eo
ra
a c
ss
Note
ce
le
un
pt
an
d
itte
Do not remove securing plate -2- from cable reel.
y li
rm
ab
pe
ility
ot
– Place Bowden cable with long sleeve -3- beneath diagonal
wit
, is n
Bowden cable -4-.
h re
hole
spec
– Guide sleeve of Bowden cables in cable reel -1- -arrows-.
es, in part or in w
t to the co
– Guide Bowden cable with short sleeve in Bowden cable
mounting of front guide rail.
rrectness of i
Do not feed Bowden cable on guide roller yet.
l purpos
– Guide Bowden cable with long sleeve in Bowden cable mount‐

ing of rear guide rail.
nform
ercia
Do not feed Bowden cable on guide roller yet.

m
a
com
tion in
Note
r
te o
thi
s
iva
do
The Bowden cable ends should now be located at the top of the
r
rp
cum
window regulator as the clamping jaws can only be installed in
fo
en
g
the upper position in the guide rails. If necessary, pull Bowden

n
t.
yi Co
op
cable out of cable reel slightly. C py
t. rig
gh ht
pyri by
Vo
co
Installation of carrier with clamping jaws
by lksw
cted agen
Prote AG.
– Place carrier with clamping jaw on side of guide rail. Clamping
jaw should point towards top of window regulator.
– Insert crimped Bowden cable ends in carrier -3-.

– First insert bottom Bowden cable -1- in upper deep groove.
– Then insert top Bowden cable -2- in lower shallow groove.
Note
The Bowden cables should be crossed over.
– Fold up carrier with clamping jaw -1- in -direction of arrow-

towards guide rail -2-.
– Install second carrier with clamping jaw -1- as described.
Feeding Bowden cable onto guide roller

Golf 1998 ➤
General body
en Arepairs,
G . Volkswaexterior
gen AG - Edition 08.2003
ag does
ksw not
y Vol gu
– Check the 4 ends of the Bowden cable sleeve areseseated
db cor‐ ara
nte
rectly in the mountings -arrow-. thori eo
au ra
c
– Place Bowden cable -1- on eccentric camsssof guide rollers
ce
le
-2- as shown in diagram.
un
pt
an
d
itte
y li
– All eccentric cams should be turned to the smallest stroke,
erm
ab
otherwise it will be difficult to fit the Bowden cable to the last
ility
ot p
guide roller.
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove securing plate -2- off cable reel -1-.
– Pull both carriers with clamping jaws to bottom end of guide
ss
rails. As this is done, the Bowden cable will be fed automati‐
o
cial p
f
cally into the groove of the guide rollers.
inform
mer
– Check position of Bowden cable.
atio
om
n
The Bowden cable should be located correctly in the groove of all
c
i
or
n
4 guide rollers.
thi
te
sd
iva
o
– Move carrier with clamping jaws up and down on guide rails
pr
cum
r
fo
several times to check correct function.
en
ng
t.
yi Co
op
Vehicles with electric window regulators C py
t. rig
gh ht
yri by
– Place foam underlay elements included in the repair set be‐ cop Vo
by lksw
tween window regulator motor and assembly carrier. Prote
cted AG.
agen
– Install window regulator motor.

– Tighten bolts to 3.5 Nm.
Vehicles with mechanical window regulators
– Fit relay element for cable reel -1-.

– Install seals -2-.
– Install crank -2-. If necessary, align relay element for cable reel
and crank. To do this, the relay element should be turned until
the crank and relay element are correctly positioned in relation
to each other.
– Tighten bolts -1- to 3.5 Nm.
– Install assembly carrier with window regulator ⇒ page 146 .
– Slide door window in clamping jaws without additional force
and align to rear window guide.
– Tighten bolts of clamping jaws to 10 Nm.
2. Door window 167

Golf 1998 ➤
66 – Exterior equipment
1 Removing and installing wheel hous‐
ing liner
1.1 Front wheel housing liner gen AG. Volkswagen AG d

wa oes
olks not
byV gu
ara
ed
1 - Wheel housing liner ho
ris nte
eo
t
❑ Material - PP/EPDM au ra
c
ss
❑ Removing:
ce
le
un
pt
an
d
itte
– Remove wheel. Wheel
y li
erm
ab
bolt tightening torque =
ility
ot p
120 Nm.
wit
is n
h re
– Unscrew cross-head
ole,
spec
screws
t to the co
(qty. 12) and pull off
wheel housing liner.
rrectne
2 - Spreader nut
ss o
cial p
f
4 - Speed nut
inform
❑ Fitted to bumper cover
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.
168 Rep. Gr.66 - Exterior equipment

Golf 1998 ➤
1.2 Rear wheel housing liner
1 - Wheel housing liner

❑ Removing:
– Remove wheel. Wheel
bolt tightening torque =
120 Nm.
– Unscrew cross-head
screws
(qty. 7) and pull off
wheel housing liner.
2 - Speed nut
❑ Fitted to bumper cover n AG. Volkswagen AG do
lkswage es n
3 - Cross-head screw d byV
o ot g
ua
ran
ir se tee
4 - Spreader nut utho
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 lksw
by
cted agen
Prote AG.
1. Removing and installing wheel housing liner 169

Golf 1998 ➤
2 Exterior mirror
2.1 Tools
♦ Removal lever -80-200-
2.2 Assembly overview AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
d
1 - Mirror housing horise nte
eo
ut
❑ Removing ⇒ page 171 . ss a ra
c
❑ Material: ABS
ce
le
un
pt
an
d
itte
2 - Bolt
y li
erm
ab
❑ 10 Nm
ility
ot p
wit
is n
3 - Cover for exterior mirror
h re
ole,
spec
4 - Bolt
t to the co
5 - Clip
6 - Connector
rrectne
7 - Insulation
8 - Mirror glass
ss o
❑ Removing:
cial p
f inform
– First press mirror glass
mer
down then up (special

atio
m
tool 80-200). Protect

o
n
c
i
or
mirror housing against

thi
te
damage.
sd
iva
o
pr
cum
r
❑ Installing:
fo
en
ng
t.
yi Co
– Insert mirror glass with . Cop py
guide studs into mounts
ht rig
rig ht
by
and press on. copy Vo
by lksw
cted agen
Prote
❑ Press only on centre of
AG.
mirror - always use pro‐

tective gloves

Golf 1998 ➤
2.3 Removing mirror housing

– Fold exterior mirror forwards to ease removal and installation.
– Position mirror glass -2- vertically (otherwise mirror housing
can catch on mirror glass when pulling off).
– Insert screwdriver -5- through assembly hole of mirror carrier
up to clip -4-.
– Press screwdriver -5- in -direction of arrow- (this will cause the
clip -4- to release the mirror housing).
– Pull mirror housing -1- upwards off mirror carrier -3-.
AG. Volkswagen AG d
agen oes
ksw
2.4 Removing exterior mirror (mechanical type) d byV
ol not
gu
ara
ise nte
or eo
h
aut ra
ss c
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Exterior mirror 171

Golf 1998 ➤
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
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
riv
– Unscrew mirror adjuster from inside of door trim -arrows-.

p
cum
for
en
ng
– Remove screw -1- and unclip cover -2-.

t.
yi Co
Cop py
.
– Pull insulating foam off mirror quarter panel
ht rig
rig ht
py by
co Vo
– Remove screw -3- and pull exterior mirror -4- off front door.
by lksw
cted agen
Prote AG.

Golf 1998 ➤
3 Roof mouldings
3.1 Roof moulding
1 - Roof moulding
❑ Do not bend roof mould‐
ing agen
AG. Volkswagen AG d
oes
lksw not
❑ Installing: by Vo gu
a
d ran
ise
– Alignuroof
tho moulding to B-
r tee
or
pillar
ss (2-door) or C-pillar
a ac
(4-door) and fit further
ce
le
un
forwards.
pt
an
d
itte
y li
rm
ab
2 - Cover strip
pe
ility
❑ Installing:
ot
wit
, is n
h re
– Insert cover strip onto
hole
spec
stop in pocket of roof
es, in part or in w
moulding and then
t to the co
press into roof channel.
To aid installation a lubricant
rrectness of i
can be used.
l purpos
3 - Rivet
4 - Angle strip
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.
3. Roof mouldings 173

Golf 1998 ➤
4 Roof rail
1 - Roof rail
❑ Assembly sequence: A-
pillar, C-pillar and D-pil‐
lar
2 - Hexagon nut
❑ Qty. 6
❑ 23 Nm
3 - Cone washer
4 - Cap
❑ Insert cover cap in
round clip first and then
press in double clip
5 - Backing plate
6 - Cap
❑ Centre
❑ Press cover cap on roof
rail base
❑ With retaining pins,
cone waster, seal and
locking cap (locking cap en AG. Volkswagen AG
is included in items sup‐
olks
wag does
not
plied with spare epart)
d byV gu
ara
ris nte
8 - Bolt autho eo
ra
ss c
❑ Qty. 12
ce
le
un
pt
❑ 20 Nm
an
d
itte
y li
9 - Welded nut
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
4.2 Installing retaining bracket

– Insert retaining bracket -1- in roof hole and press in until lock‐
rrectne
ing cap -2- engages in roof hole. All locking lugs must engage.
ss o
Note
cial p
f inform
mer
The locking cap on the retaining bracket should not be turned

atio
m
before it is engaged.
o
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.

Golf 1998 ➤
– Press retaining bracket -1- onto inner side part and secure with
bolts -3- (20 Nm).
Note
The bolted connections are next to each other on the middle re‐
taining bracket.
– Unscrew locking cap -2- from outside. Use suitable tool if nec‐
essary.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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
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
o
by c lksw
cted agen
Prote AG.
4. Roof rail 175

Golf 1998 ➤
5 Trim
5.1 Removing and installing radiator grille

Assembly overview
1 - Radiator grille
❑ Golf
❑ Material-ASA
2 - Locking hook
3 - Cross lug
4 - Retaining pin
5 - Centre fixing point
6 - VW emblem
❑ Clipped into radiator
grille
7 - Radiator grille
❑ Bora
❑ Material-ASA
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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 lksw
by
cted agen
Prote AG.

Golf 1998 ➤
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
ercia
Removing
m
at
om
ion
– Separate release lever from bonnet lock

c
in t
or
⇒ “1.3 Removing release lever”, page 108 .

his
ate
do
riv
– Release locking hooks ⇒ Item 2 (page 176) using screwdriver.

p
cum
for
en
g
– Pull cross lug ⇒ Item 3 (page 176) out of lock carrier and re‐
n
t.
yi Co
op
move radiator grille upwards. C py
t. rig
gh ht
yri by
Installing cop Vo
by lksw
cted agen
Prote
– Align radiator grill to centre fixing point ⇒ Item 5 (page 176) ,
AG.
insert lower pin ⇒ Item 4 (page 176) in bumper cover and clip
in at top.
5. Trim 177
Golf 1998 ➤
6 Bump strips
6.1 Renewing side bump strips

– Warm side bump strip with hot air blower before removing.
– Clean exterior panel with solvent, treat with silicone remover
and then dry off.
– Pull off protective foil, attach side bump strip lightly and then
press on with force. Working temperature approx. 20° C.
1 - Front door bump strip

❑ Left and right-hand
bump strips have a dif‐
ferent hole pattern
❑ Self-adhesive
❑ Material PP/EPDM
❑ The centring lugs
and
⇒ Item 4 (page 178) de‐
termine the position of
the bump strips
2 - Pins
❑ Prevent twisting lkswage es n
o ot g
yV ua
3 - Centring lug ir se
d b ran
tee
tho
or
4 - Centring lug au ac
ss
ce
e
5 - Pins
nl
pt
du
an
❑ Prevent twisting
itte
y li
erm
ab
6 - Rear door bump strip
ility
ot p
wit
❑ Left and right-hand
, is n
h re
bump strips have a dif‐
hole
spec
ferent hole pattern
es, in part or in w
❑ Self-adhesive
t to the co
❑ Material PP/EPDM
❑ The centring lugs
rrectness of i
⇒ Item 4 (page 178) de‐
l purpos
termine the position of

the bump strips
nform
ercia
7 - Protective foil
m
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.

Golf 1998 ➤
7 Special body parts, Golf

agen
AGGTI
. Volksw(132
agen AG
does
kW) and Golf R32
db
y Volksw not
gu
ara
e nte
ris
tho eo
au ra
c
ss
7.1 Safety requirements
ce
le
un
pt
an
d
itte
♦ These special body parts were developed to meet specific
y li
erm
ab
technical requirements for the Golf GTI (132 kW) and R32. All
ility
ot p
of these special body parts should be replaced with the rele‐
wit
vant genuine part in all cases.
is n
h re
ole,
♦ Without these special body parts, the vehicle does not comply
spec
with the traffic regulations.
t to the co
7.2 Tools
rrectne
equipment required
ss o
cial p
f
♦ Cutting tool -V.A.G 1351-
inform
mer
♦ Removal kit for flush bon‐
atio
ded windows -
om
n
V.A.G 1474 A-
c
i
or
n thi
te
sd
♦ Windscreen removal kit -
iva
o
r
V.A.G 1755-
p
cum
r
fo
en
ng
♦ Double cartridge gun -

t.
yi Co
op
VAS 5237-
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7.3 Materials
♦ 2K window adhesive -DA 004 600 A2- 8), 9)
♦ Static mixer with tapered -D 002 001-

nozzle
7. Special body parts, Golf GTI (132 kW) and Golf R32 179
Golf 1998 ➤
♦ Activator -D 181 801 A1- 7)
♦ Primer -D 181 711 A1-
♦ Cleaning solution -D 009 401 04- 7)
♦ Primer applicator -D 009 500 25- 7)
♦ Adhesive remover -D 002 000 10- 7) AG. Volkswagen AG d

agen oes
olksw not
V
♦ Cutting cord -357 853 999 A- ed by gu
ara
ris nte
ho eo
aut ra
7) Materials are stored in the box D 004 700. ss c
ce
e
nl
8) Observe curing time ⇒ page 189 .
pt
du
an
itte
y li
9) Double cartridge gun -VAS 5237- must be used to apply these materials.
erm
ab
ility
ot p
wit
, is n
h re
Golf GTI
hole
spec
es, in part or in w
1- Front spoiler ⇒ page 180
t to the co
2- Side skirt ⇒ page 182
3- Rear spoiler ⇒ page 180
rrectness of i
4- Roof spoiler ⇒ page 186
l purpos
nform
mercia
at
om
io
Golf R32
n
c
in t
or
his
e
1- Front bumper ⇒ page 110

at
do
priv
c
2- Side skirt ⇒ page 182
um
for
en
ng
t.
yi
3- Rear bumper ⇒ page 118
Co
Cop py
t. rig
gh
4- Roof spoiler ⇒ page 186
ht
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Vo
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Prote AG.
7.5 Front and rear spoiler (Golf GTI)

Golf 1998 ➤
1 - Front spoiler
❑ Material PU-R-RIM
❑ Engaged to bumper
cover
AG. Volkswagen AG d
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2 - Rear spoiler Vol
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❑ Engaged sa
uto bumper
t ra
c
cover s
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nl
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erm
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t to the co
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ate
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for
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Cop py
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Prote AG.
Golf 1998 ➤
7.6 Side skirt (Golf GTI, Golf R32)

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7.6.1 Assembly overview d b ara
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au ra
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1 - Side skirt
ce
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nl
pt
du
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itte
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erm
ab
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❑ Installation instructions
wit
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⇒ page 189 .
h re
hole
spec
❑ Material PU-R-RIM es, in part or in w
t to the co
2 - Lower primer surface on
side skirt
3 - Bolt
rrectness of i
❑ Qty. 2
l purpos
❑ 2 Nm
4 - Upper primer surface on
nform
ercia
side skirt
m
at
om
i
5 - Sill panel
on
c
in t
or
❑ Preparation
his
ate
⇒ page 188
do
priv
cum
or
6 - Upper primer surface on sill

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panel
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Cop py
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7 - Lower primer surface on sill
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panel cop Vo
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❑ Curing time
⇒ page 189

Golf 1998 ➤
7.6.2 Removing side skirt
AG. Volkswagen AG d
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aut ra
ss c
ce
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pt
du
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itte
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ab
ility
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es, in part or in w
t to the co
WARNING
rrectness of i
When removing parts of body kit, cutting wire should not be

l purpos
used due to the risk of damage to the painted areas.

nf
ercia
or
– Clean dirt from all joints so that no parts of the body kit are
m
m
atio
damaged in the painted area.

om
n in
or c
– Sever bond between sill panel at top of side skirt to prevent

thi
te
paint damage being caused by the cutting cord.

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iva
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cu
– Remove two bolts -1- in area of front wheel housing.

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– Sever the three lower bonded areas of the side skirt using the Cop py
pull handles and cutting cord.
ht. rig
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Prote AG.
Golf 1998 ➤
AG. Volkswagen AG d
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au ra
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un
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d
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rm
ab
pe
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ot
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– Cut through the upper adhesive bead using the pull handles
hole
and cutting cord. spec

es, in part or in w
t to the co
– Remove side skirt.
rrectness of i
l purpos
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com
tion in
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te o
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do
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Cop py
t. rig
gh ht
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Vo
co lksw
by
cted agen
Prote AG.

Golf 1998 ➤
7.6.3 Installing side skirt
1 - Primer surface on side skirt

2 - Upper primer surface on sill
panel
❑ Dimension a = 12 mm
❑ Dimension b = 10 mm
❑ The edge of the stone
chip protection can be
used as a reference
point for the upper edge
of the primer surface.
3 - Lower primer surface on sill
panel
❑ The 3 surfaces should AG. Volkswagen AG d
agen oes
ksw
be determined by hold‐ by
Vol not
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ara
ing the side skirt in posi‐ rised
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ra
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s
4 - Lower primer surfaces on
ce
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nl
side skirt
pt
du
an
itte
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❑ 3 surfaces
erm
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ility
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5 - Upper adhesive bead
wit
, is n
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hole
spec
♦ Width = 5 mm
es, in part or in w
t to the co
residual material on sill
panel)
rrectness of i
6 - Lower adhesive bead
l purpos
❑ Apply adhesive in two

beads of 19 mm x 30
mm and a height of 7
nf
ercia
o
mm to one surface
rm
m
atio
m
❑ 3 surfaces
o
n in
or c
thi
te
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t.
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Cop py
t. rig
gh ht
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Prote AG.
Golf 1998 ➤
7.7 Roof spoiler (Golf GTI, Golf R32)
7.7.1 Assembly overview swage

es n
olk ot g
byV ua
d ran
ir se tee
1 - Roof spoiler utho
or
a ac
❑ Removing ⇒ page 186 ss
ce
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nl
pt
du
an
itte
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erm
ab
⇒ page 189 .
ility
ot p
wit
, is n
h re
hole
2 - Primer surface on spoiler
spec
es, in part or in w
3 - Outline of roof spoiler in situ
t to the co
4 - Primer surface on rear lid
and residual material
rrectness of i
❑ Preparation
⇒ page 188
l purpos
nf
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orm
m
atio
om
n in
or c
thi
te
sd
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m
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7.7.2 Removing roof spoiler
WARNING
When removing parts of body kit, cutting wire should not be

used due to the risk of damage to the painted areas.
– Clean dirt from all joints so that no parts of the body kit are
damaged in the painted area.
– All painted areas around contact area and gap between roof
and rear lid should be masked off.

Golf 1998 ➤
– Position reel device in position as shown in diagram and attach

one cord end
– Place cutting cord around spoiler so that cord rests on joint
between spoiler and rear lid and then secure second cord end
on wiper shaft.
– When cutting free, guide cutting cord into joint using a plastic
wedge.
– In the position shown, the spoiler should be cut free up to ap‐
prox. the centre of the vehicle.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Then the reel
s au device is changed over as shown in the diagram ra
c
and the cord ends reversed. The spoiler is then cut free up the
s
ce
e
nl
centre of the vehicle from the other side.
pt
du
an
itte
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– Remove spoiler.
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
7.7.3 Installing roof spoiler

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.
Golf 1998 ➤
1 - Roof spoiler
⇒ page 189 .
2 - Primer surface on spoiler
❑ Adhesive bead with
width of 3 mm and
height of 5 mm
3 - Outline of roof spoiler in situ
❑ The spoiler should be
positioned on the rear lid
and the body around the
contact area masked off
4 - Primer surface on rear lid
and residual material
❑ Preparation
⇒ page 188
❑ Dimension a = 7 mm
❑ Dimension b = 10 mm
AG. Volkswagen AG d
agen oes
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d b ara
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au ra
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un
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an
d
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spec
t to the co
7.8 Preparing body kit component for bond‐

ing
rrectne
Note
ss o
cial p
f in
Remaining material serves as adhesion base for newly applied

form
mer
adhesive sealing compound. Keep dirt and grease off of bonding

atio
surfaces.
om
n
c
i
or
n thi
e
Exception: if bonding is not performed immediately after cutting

t
sd
va

i
o
pr
cum
r
tivator -D 181 801 A1- .

fo
en
ng
t.
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Cop py
t. rig
WARNING opyri
gh by
Vo
ht
c by lksw
cted
Activator must not come into contact with paint or damage to
agen
Prote AG.

Golf 1998 ➤
Note
If the body kit part has been repaired or partially renewed, the
area concerned must be cleaned and primed again after painting.
7.9 Installation instructions

The surfaces to be primed for the body kit parts should be com‐
pletely clean.
– Adhesive residue should be removed using adhesive remover
-D 002 000 10- .
– Soak cloth in silicon remover -LSE 020 100 A3- .
– Clean area of application for adhesive bead twice thoroughly
using cloth applied with solution and allow to dry.
– Now apply primer using applicator -D 009 500 25- equally in
one stroke.
♦ Drying time approx. 10 minutes
– Adhesive material should be applied to the primed areas of the
body kit parts.
WARNING
Body kit parts should be installed within 10 minutes, or bonding

properties of adhesive will be impaired.
♦ Shutlines should be kept to an absolute minimum, up to ap‐

prox. 1 mm.
AG. Volkswagen AG d
agen oes
♦ Use adhesive tape to secure body kit part in position
olkswhile
w not
yV gu
curing. se
d b ara
nte
ri
ho eo
7.10 Minimum curing time ss
aut ra
c ce
e
nl
The minimum curing time for newly bonded special body parts is
pt
du
an
3 hours.
itte
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erm
ab
The minimum curing time is the period between bonding the ac‐
ility
ot p
cessory parts to installation. During this time, the vehicle must be

wit
, is n
parked on a hard level standing at room temperature (at least15°

h re
hole
C).
spec
es, in part or in w
t to the co
WARNING
Vehicle is safe to use only after the minimum curing time has
rrectness of i
elapsed.
l purpos
7.11 Touching up paint damage

nf
ercia
orm
m
atio
Paint structure must be restored according to specifications in the

om
“Paint” workshop manual.

n in
or c
thi
e
The following repair method is suitable for paint finish damaged

t
sd
iva
in areas which are not visible:

o
r
rp
cu
o
m
f
en
ng
– Painting over twice (wet-on-wet) with glass/paint primer -D

t.
yi Co
009 200 02- - flash-off time = at least 10 minutes. Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Golf 1998 ➤
7.12 Cleaning off excess adhesive sealingagen

AG. Volkswagen AG d
oes
material by
Volksw not
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a d ran
ise
– Use of adhesive remover -D 002 000 10- uas
tho a cleaning solution
r tee
or
is recommended. Observe the appropriate
ss
a safety precautions ac
when performing this work.
ce
e
nl
pt
du
an
– First clean painted surface as much as possible using a dry
itte
y li
cloth. Remove residue using adhesive remover -D 002 000
erm
ab
10- .
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

K0051007220-General Body Repairs Exterior

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0051007220

1.4 Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.7 Assembly overview - noise insulation (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.6 Assembly overview - bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.7 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.9 Removing and installing locking button for locking rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.4 Adjusting glass panel for sliding/tilting sunroof (height adjustment) . . . . . . . . . . . . . . . . . . 82

2.5 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.6 Removing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.7 Removing sliding headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

2.8 Removing drive mechanism for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

2.9 Adjusting drive mechanism for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . 86

2.10 Removing pre-selector control for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.12 Adjusting parallel running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.14 Removing coulisse guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3 Sliding/tilting sunroof with glass panel (Meritor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.1 Assembly overview - sliding/tilting sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . 93

3.2 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

3.3 Installing glass panel for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3.4 Adjusting glass panel for sliding/tilting sunroof (height adjustment) . . . . . . . . . . . . . . . . . . 96

3.5 Adjusting panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

3.11 Removing pre-selector control for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.3 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1.5 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.7 Assembly overview - side window, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1.8 Removing undamaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1.9 Removing damaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.10 Installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.11 Assembly overview - side window, estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2.5 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

2.8 Fitting door window to window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

force limitation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

2.10 Overriding resistance in event of force limitation intervention . . . . . . . . . . . . . . . . . . . . . . 160

1 Removing and installing wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1 - Lock carrier with attach‐

– Remove front bumper

– Disconnect hose for

– Unbolt radiator and con‐

– Secure radiator and

– Readjust headlights. rrectnes

4 - Hole in side panel

5 - Radiator and condenser

2 Rep. Gr.50 - Body - front

1.3 Lock carrier - service position

– Remove front bumper cover ⇒ page 106

– Disconnect Bowden cable on lock.

1.4 Assembly overview - front wing

– Remove wheel housing

– Heat wing in area of A-

4 Rep. Gr.50 - Body - front

1.5 Wing dimensions

Distance between wings

Horizontal and vertical offset between wing tips: