Volkswagen Golf Variant / Jetta. Manual - part 8

 

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Volkswagen Golf Variant / Jetta. Manual - part 8

 

 

2.1

Tools

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

2.2

Assembly overview - rear lid

1 - Hinge cover
2 - Wiring harness
3 - Rear lid

❑ Removing and installing

⇒ page 30

❑ Adjusting 

⇒ page 33

4 - Rear lid trim

❑ Removing and installing

⇒  General body repairs,

exterior; Rep. Gr.  70 ;

Removing and installing

rear lid trim

5 - Adjustment buffer

❑ Left and right
❑ When installing, turn 90°

anti-clockwise -arrow-

❑ Adjusting 

⇒ page 33

6 - Hexagon nut

❑ Qty. 2
❑ 22 Nm

7 - Lid hinge

❑ Removing and installing

⇒ page 31

8 - Rubber buffer
9 - Bolt

❑ Qty. 3
❑ 22 Nm

10 - Gas strut

❑ Removing 

⇒ page 30

❑ Releasing gas

⇒ page 31

2. Rear lid (saloon)    

29

 

12 - Locking wedge

❑ Removing and installing 

⇒ page 32

13 - Pop rivet nut
14 - Base for registration plate

❑ Different versions are possible.
❑ Assignment ⇒  Parts catalogue “ETKA”

2.3

Removing and installing rear lid

2.3.1

Removing

– Open rear lid.
– Remove rear lid trim ⇒  General body repairs, interior; Rep.

Gr.  70 ; Rear lid trim .

– Disconnect connectors -1- and pull wiring -2- with rubber

grommet out of lid.

– Loosen hexagon nuts -3- on left and right lid hinges (do not

unbolt completely).

Further dismantling requires the assistance of a second mechan‐

ic.
– Detach gas struts -4- on left and right of rear lid 

⇒ page 30

 .

– Now, and only now, unbolt bolts -3- and remove rear lid.

2.3.2

Installing

Install in reverse order of removal.
Specified torque for rear lid hexagon nut: 22 Nm.
Adjust rear lid 

⇒ page 33

 .

Before closing rear lid, check function of lid release components.

2.4

Removing gas strut

– Open rear lid and support it.

30

 

– Pull gas strut -1- off ball-head pins -3- and -4-.
– Slide spring clip -2- back immediately after removing gas strut

-1-.

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.

Releasing gas from gas strut 

⇒ page 31

2.5

Releasing gas from gas strut

– Clamp gas strut in vice in area marked -x- = 50 mm (2 in).

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.

2.6

Removing and installing lid hinge

Note

Removal and installation is described for hinge on right of lid.

Follow same instructions for hinge on left of lid as appropriate.

2.6.1

Removing

– Remove rear lid 

⇒ page 30

2. Rear lid (saloon)    

31

 

Installing

Install in reverse order of removal.
Specified torque for lid hinge bolts: 22 Nm
Adjust rear lid 

⇒ page 33

 .

Before closing rear lid, check function of lid release components.

2.7

Removing and installing striker pin

2.7.1

Removing

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

Rep. Gr.  70 ; Luggage and load compartment trim .

– Remove bolts -1- and remove striker pin -2-.

2.7.2

Installing

– Install striker pin -2-.

Specified torque for bolts -1-: 23 Nm.

Further installation is performed in reverse order of removal.

32

 

 

 

 

 

 

 

 

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