Volkswagen Golf / Golf Plus. Manual - part 224

 

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Volkswagen Golf / Golf Plus. Manual - part 224

 

 

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55 – Bonnet, rear lid

1

Bonnet

1.1

Tools

Special tools and workshop equipment required
♦ Torque wrench 5...50 Nm -V.A.G 1331-

♦ Removal lever -80-200-

General body repairs, exterior - Edition 04.2008

1. Bonnet    

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1.2

Assembly overview - bonnet

1 - Bonnet

❑ Removing and installing

⇒ page 19

❑ Adjusting 

⇒ page 26

2 - Adjustment buffer

❑ Qty. 2
❑ Adjusting 

⇒ page 26

3 - Stop buffer

❑ Qty. 2

4 - Insulation

❑ Removing and installing

⇒ page 22

5 - Guide

❑ Qty. 2

6 - Hinge

❑ Removing and installing

⇒ page 20

❑ Adjusting 

⇒ page 26

7 - Gas strut

❑ Removing 

⇒ page 20

❑ Releasing gas

⇒ page 20

8 - Seal

❑ Secured with 17 clips to

inside of bonnet

General body repairs, exterior - Edition 04.2008

18

     Rep. Gr.55 - Bonnet, rear lid

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1.3

Removing and installing bonnet

1.3.1

Removing

– Remove left and right washer jets -6- ⇒  Electrical system;

Rep. Gr.  92 ; Window wiper/washer system; Windscreen

washer system; Removing and installing windscreen washer

system jets .

– Unclip line -2- from hinge -3- and bonnet -5-.
– Pull line -2- out through aperture in bonnet -5-.
– Loosen hexagon nuts -1- on left and right (do not remove).
Further dismantling requires the help of a second mechanic.
– Disconnect gas strut -4- at bonnet -5- 

⇒ page 20

 .

– Now remove hexagon nuts -1- and lift lid -5- out of hinges

-3-.

1.3.2

Installing

Install in reverse order of removal.

General body repairs, exterior - Edition 04.2008

1. Bonnet    

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– Specified torque for bonnet hexagon nut: 22 Nm.
– Adjusting bonnet -1- 

⇒ page 26

 .

– Route line -2- in an arc -arrow-. If line is installed twisted it will

be kinked.

1.4

Removing gas strut

– Open rear lid and support it.
– Position a small screwdriver beneath spring clip -2-.
– Raise spring clip -2- until it can be moved over ball socket in

direction of -arrow-.

– Pull gas struts -1- from ball-head pins -3- and -4-.
After removing gas strut -1-, slide spring clip -2- back immediately.

WARNING

Proceed with care if gas strut is reused. Spring clip must not

be levered completely out of ball socket, as it will otherwise be

damaged. Gas strut will spring out of mounting, causing dam‐

age or injury to operator.

– Specified torque for ball-head pins -3- and -4-: 22 Nm.
– Releasing gas from gas strut 

⇒ page 20

1.5

Releasing gas from gas strut

– Clamp gas strut in vice in area x = 50 mm.

WARNING

Clamp gas strut only within area -x-; otherwise danger of ac‐

cident!

– Saw through cylinder of gas strut within first third of cylinder's

overall length using piston rod end of cylinder as reference

point.

Note

Wear eye protection when sawing.

Cover area of saw cut with a cloth.

Dispose of oil and cloth via existing disposal channels.

1.6

Removing and installing flap hinge

Note

The removal and installation sequence is only described for the

left hinge. The removal and installation of the right hinge is similar.

General body repairs, exterior - Edition 04.2008

20

     Rep. Gr.55 - Bonnet, rear lid

 

 

 

 

 

 

 

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