Service

Workshop Manual
Fox 2004 ➤
General body repairs, interior
Edition 04.2011

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
68 - Internal Equipment
69 - Passenger protection
70 - Finishing/insulation
72 - Seat Structure
74 - Seat lining and upholstery

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.
 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

Contents

68 - Internal Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Internal rearview mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Internal rearview mirror - removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Internal rearview mirror support plate - glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Internal rearview mirror with automatic anti-glare - general assembling overview . . . . . . . . 2
1.4 Internal rearview mirror with automatic anti-glare - remove and install . . . . . . . . . . . . . . . . 4
1.5 Mirror fastening support (with automatic anti-glare) - install . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Object compartment, covers and lids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Center console - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Cup holder on seat cushion (Europe only)- assembly overview . . . . . . . . . . . . . . . . . . . . 9
2.3 Parking brake lever handle - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Tray at the passenger's side (instrument panel without glove compartment) - remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Glove compartment (Europe only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Central frame on the instrument panel (instrument panel without glove compartment) . . . . 12
2.7 Central frame on instrument panel (with glove compartment - Europe only) . . . . . . . . . . . . 14
2.8 Luggage retaining net . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9 Parasol - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Roof`s Safety Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Roof safety handle - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Door sill's trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Door sill's trims (2 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Door sill trims (4 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

69 - Passenger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1 safety belts - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 Safety measures for belt pre-tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2 Belt pre-tensioner - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Pre-tensioner units - elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Safety belts - checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Check points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Mooring points of the children's seat (ISOFIX) - checking after accidents . . . . . . . . . . . . . . 33
3 Front safety belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Front seat belt „2-door“ (with pre-tensioner) - assembly overview . . . . . . . . . . . . . . . . . . . . 34
3.2 Front seat belt „2-door“ (with pre-tensioner) - remove and install . . . . . . . . . . . . . . . . . . . . 35
3.3 Front seat belt „2-door“ (without pre-tensioner) - assembly overview . . . . . . . . . . . . . . . . 36
3.4 Front seat belt „2-door“ (without pre-tensioner) - remove and install . . . . . . . . . . . . . . . . . . 38
3.5 Front seat belt „4-door“ (without pre-tensioner) - assembly overview . . . . . . . . . . . . . . . . 38
3.6 Front seat belt „4-door“ (without pre-tensioner) - remove and install . . . . . . . . . . . . . . . . . . 40
3.7 Belt height adjustment „2 and 4-door“ - remove and install . . . . . . . . . . . . . . . . . . . . . . . . 41
3.8 Fastening point of the front belt - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.9 Front seat belt latch (Europe only) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.10 Fastening of the front belt - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Rear safety belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 Rear seat belt (with automatic inertia reel) - assembly overview . . . . . . . . . . . . . . . . . . . . 46
4.2 External rear seat belt (with automatic inertia reel) - remove and install . . . . . . . . . . . . . . 46
4.3 Rear seat belts (without automatic inertia reels) - assembly overview . . . . . . . . . . . . . . . . 47
4.4 External rear seat belts (without automatic inertia reels) - remove and install . . . . . . . . . . 48
4.5 Lower fastening point of the rear belt - removal and installation . . . . . . . . . . . . . . . . . . . . 49
4.6 Lap belt with dual latch „2 and 4-door“ (rear seat without longitudinal adjustment) - remove
and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7 Lap belt with dual latch „2 and 4-door“ (rear seat with longitudinal adjustment) - remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Contents i
 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

4.8 Single latch„2-door“ (split rear set with longitudinal adjustment - Europe only) - remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1 Installation locations - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.2 Safety measures for working with Airbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.3 Airbag ignition devices after an accident - replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.4 Ignition device for driver's airbag N95 (steering wheel with 3 spokes) - removal and
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.5 Ignition device for driver's airbag N95 (steering wheel with 4 spokes) - removal and
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6 Connector of the airbag coil and return spring with sliding ring F138 - remove and install
........................................................................ 64
5.7 Trigger 1 for front passenger's airbag N131 - remove and install . . . . . . . . . . . . . . . . . . . . 65
5.8 Driver's/passenger's side airbag trigger N199 / N200 - remove and install . . . . . . . . . . . . 67
5.9 Control unit for the airbag J234 - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.10 Passenger's side airbag crash sensor G180 and Driver's side airbag crash sensor G179 -
remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.11 Components - adapting/verifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6 Deactivation of the airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1 Ignition device 1 for the front passenger airbag N131 - blocking or activation . . . . . . . . . . 73

70 - Finishing/insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1 Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.2 Instrument panel - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Instrument panel (with glove compartment - exclusive Europe) - remove and install . . . . 77
1.4 Cross support/Instruments panel - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . 80
1.5 Instrument panel cover - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.6 Steering column covering - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.7 Steering column covering with adjustment - remove and install . . . . . . . . . . . . . . . . . . . . 89
2 Doors' linings (2 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.2 Driver's side front door lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.3 Front passenger's side door lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3 Doors' linings (4 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.2 Front door lining - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3 Front door lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4 Rear door lining - general overview of assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.5 Rear door lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Lining of columns and sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Column A lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3 Column B lining (2 doors) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.4 Column B linings (4 doors) - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.5 Column B lining (4 doors) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.6 Column B lining (4 doors) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.7 Column C lining (2 doors) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.8 Pillar C lining (4 doors) - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.9 Column C lining (4 doors) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.10 Side lining (2 doors) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5 Linings of the luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.2 Rear lid lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3 Luggage compartment cover - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.4 Lower lining and cover of the rear panel - removal and installation . . . . . . . . . . . . . . . . . . 122

ii Contents
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General body repairs, interior - Edition 04.2011

5.5 Luggage compartment side lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

6 Bonnet noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.1 Bonnet noise insulation - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7 Roof linings (2 ports) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.1 Pre-molded overhead lining - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.2 Pre-molded roof lining (sunroof) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . 128
8 Roof lining (4 ports) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.1 Pre-molded overhead lining - general overview of assembly . . . . . . . . . . . . . . . . . . . . . . 132
8.2 Pre-molded overhead lining - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.3 Floor lining - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

72 - Seat Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

1 Front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.1 Left front seat - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.2 Right front seat - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.3 Front seat cover - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.4 Front seat cover (with parallel height regulation) - removal and installation . . . . . . . . . . . . 155
1.5 Fire extinguisher support - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.6 Front seat head rest - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.7 Front seat backing - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.8 Front seat backrest (Europe only) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.9 Parallel height adjustment - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.10 Cable for unlocking the backing - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.11 Cable for unlocking the backing - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . 163
1.12 Front seat head rest guide - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.13 Object holder under the driver's seat - removal and installation . . . . . . . . . . . . . . . . . . . . 166
2 Rear seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Back seat - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.2 Rear seat (one-piece, without longitudinal adjustment) - assembly overview . . . . . . . . . . 168
2.3 Backing (one-piece, without longitudinal adjustment) - removal and installation . . . . . . . . 169
2.4 Rear seat (one-piece, with longitudinal adjustment) - assembly overview . . . . . . . . . . . . . . 171
2.5 Backing (one-piece, with longitudinal adjustment) - removal and installation . . . . . . . . . . 172
2.6 Folding protection assembly on rear seat (one-piece, with longitudinal adjustment) -
assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.7 Folding protection assembly on rear seat (one-piece, with longitudinal adjustment) - remove
and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.8 Rear seat (two-piece, with longitudinal adjustment) - assembly overview . . . . . . . . . . . . . . 177
2.9 Backing (two-piece) - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.10 Rear seat (split, with longitudinal adjustment - Europe only) - assembly overview . . . . . . 179
2.11 Backrest (split - Europe only) - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.12 Backrest (split - Europe only)- remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.13 Seat rail - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.14 Seat backing stop (without longitudinal adjustment) - assembly overview . . . . . . . . . . . . . . 184
2.15 Seat backing stop (without longitudinal adjustment) - removal and installation . . . . . . . . . . 185
2.16 Back seat head rest - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.17 Rear seat head rest - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.18 Rear seat head rest guide - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.19 Rear seat rest unlocking button - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 189

74 - Seat lining and upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1 Linings, stuffing of front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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1.2 Front seat backing lining and stuffing - removal and installation . . . . . . . . . . . . . . . . . . . . 190
1.3 Lining and stuffing of the front backing - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . 192
1.4 Front seat backing lining and stuffing - removal and installation . . . . . . . . . . . . . . . . . . . . 193
2 Front seat heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.1 Driver / passenger seat cushion heating Z6 / Z8 - remove and install . . . . . . . . . . . . . . . . 196
2.2 Driver / passenger seat backrest heating Z7 / Z9 - remove and install . . . . . . . . . . . . . . . . 196
2.3 Lining and stuffing of the front seat head rest - removal and installation . . . . . . . . . . . . . . 197
3 Linings and stuffing of front seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3.2 Lining and stuffing of back seat (without longitudinal adjustment) - assembly overview . . 199
3.3 Lining and stuffing of back seat (without longitudinal adjustment) - removal and installation
........................................................................ 200
3.4 Lining and stuffing of back seat (with longitudinal adjustment) - assembly overview . . . . . . 201
3.5 Lining and stuffing of back seat (with longitudinal adjustment) - removal and installation . . 203
3.6 Rear seat cushion lining and filling (with longitudinal adjustment and cup holder - Europe
only) - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.7 Rear seat cushion lining and filling (with longitudinal adjustment and cup holder - Europe
only) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.8 Lining and stuffing of the back seat (one-piece) backing - assembly overview . . . . . . . . . . 205
3.9 Lining and stuffing of the back seat (one-piece) backing - removal and installation . . . . . . 206
3.10 Lining and stuffing of the back seat (two-piece) backing - assembly overview . . . . . . . . . . 208
3.11 Lining and stuffing of the back seat (two-piece) backing - removal and installation . . . . . . 209
3.12 Rear seat backrest lining and filling (split - Europe only) - assembly overview . . . . . . . . . . 210
3.13 Rear seat backrest lining and filling (split - Europe only) - removal and installation . . . . . . 211

iv Contents
 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

68 – Internal Equipment
1 Internal rearview mirror

1.1 Internal rearview mirror - removing and

installing
Removal:
– Pull the internal rearview mirror -1- up -arrow- and away of the
support plate (mirror base fastening spring).
Installation:
Installation is performed in reverse sequence to the removal.

1.2 Internal rearview mirror support plate -

glue
Special tools and workshop equipment required
♦ Glass scraper -1- (commercially available).
♦ Blade -2- (commercially available).

Materials:
♦ Metal and glass adhesive set -D 000 703 A1-
Gluing:
– Remove mirror base support plate.
– Remove the polyurethane (PUR) adhesive from the mirror
support plate using a steel brush.
– Sand the three spacing bumps on the gluing surface. To do
so, place the sandpaper (360/400 grit) over a flat surface.
– Keep the sanded surface free of dirt and grease.
– Scrape the adhesive (PUR) and the primer off the windshield
using a glass scraper until reaching the ceramic paint layer.
– Clean the gluing surface using the Adhesive remover -D 002
000 10- or the Cleaning product -D 009 401 04- .

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 Fox 2004 ➤
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WARNING

Do not damage the ceramic layer. Scratches will always be

visible.

– Cut the nylon mesh to the exact size of the mirror base.

Note

Use of protection gloves (rubber gloves) is recommended.

– Apply an ample and uniform layer of adhesive to the mirror

base.
– Position the nylon mesh over the mirror base.
– Apply more adhesive from the tube directly onto the nylon
mesh.

Note

You have 30 seconds to place the nylon mesh over the adhesive
and press the set onto the windshield.

– Strongly press the base of the mirror onto the windshield for
15 seconds (without excessive force).
– Remove excess adhesive using a cloth.

Note

The rearview mirror can be assembled after 15 minutes.

1.3 Internal rearview mirror with automatic

anti-glare - general assembling over‐
view
The internal rearview mirror with automatic anti-glare automati‐
cally darkens when the driver is affected by a light beam coming
from behind.
It is composed of a mirror and an electrical system with two photo
sensors.
The electronic system uses the photo sensors to identify light from
the front and the from behind.
If the presence of light from behind is greater than in the front, the
electronic system feeds current to the conductive lining.
The voltage supplied changes the color of the electrolyte. The
higher the voltage, the darker the electrolyte becomes.
The anti-glare feature is deactivated upon engaging the reverser
gear. This allows use of the internal rearview mirror for maneu‐
vering inside a garage without lighting.

2 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
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1 - Mirror
2 - Electrolyte lining
3 - Silver reflective layer
4 - Conductive lining
5 - Photo sensor
❑ Identifies the presence
of light from behind (rear
windshield and passen‐
ger compartment).
6 - Photo sensor
❑ Identifies the presence
of light from the front
(windshield).
7 - Electronic system
8 - Internal rearview mirror
❑ Check the operation:
Turn on the ignition.
Cover photo sensor -6-
and illuminate photo
sensor -5- with a flash‐
light, the surface of the
mirror should darken
(reverse gear cannot be
engaged).

1. Internal rearview mirror 3

 Fox 2004 ➤
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1.4 Internal rearview mirror with automatic

anti-glare - remove and install

1.4.1 Assembly overview

1 - Internal rearview mirror

2 - Right side cover
3 - Mirror base
4 - Connectors
5 - Mirror support
❑ Glued to windshield.
6 - Left side cover

4 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

1.4.2 Removal

– Detach the left -6- and right -2- side covers and remove them.
– Remove and disconnect connector-4- from the mirror base
-3-.
– Remove the mirror base -3- and the mirror -1- as one unit,
pulling down -arrow-, detaching them from the support -5-.

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1.4.3 Installation
The installation occurs in the reversal sequence of removal.

1.5 Mirror fastening support (with automatic

anti-glare) - install
Special tools and workshop equipment required
♦ Glass scraper -1- (commercially available)
♦ Blade -2- (commercially available)

Materials:
♦ Cleaning solution -D 009 401 04-
♦ Glass / body primer -D 009 200 02-
♦ 2-Component PU adhesive -D 180 KD2 A1-
The repair described prevents the windshield from having to be
replaced and uses the mirror support from the replaced wind‐
shield.
Preparing the windshield:
– Remove primer and adhesive residues all the way to the ce‐
ramic paint layer.
– Clean the gluing surface using the Cleaning solution -D 009
401 04- .
– The drying period lasts a minimum of 10 minutes.
– Apply the Glass / body primer -D 009 200 02- .
– Drying period : minimum 10 minutes, maximum 1 hour.

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Prepare the fastening support for the new/removed mirror:

– Manually remove (scrape) adhesive residues (removed sup‐
port).
– Sand the gluing surface with water using a fine grit (800-1200)
until all residues are removed from the surface.
– Clean with the Cleaning solution -D 009 401 04- .
Install the mirror fastening support:
– Apply 2-Component PU adhesive -D 180 KD2 A1- directly to
the mirror support gluing surface that was sanded and
cleaned.
– Diameter of the adhesive bead: (approx.: 2.5...3mm).
– Press the mirror base onto the prepared windshield immedi‐
ately after applying the adhesive.
– Center the mirror support into position on the ceramic pre-lay‐
er lining and fasten using adhesive tape.
Clean and remove excess adhesive:
– Carefully remove the adhesive tape 30 minutes to 1 hour after
gluing the mirror support.
– Scrape excess adhesive while still soft using a spatula.
– Completely remove the remaining excess adhesive using a
cloth moistened with Cleaning solution -D 009 401 04- .

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2 Object compartment, covers and lids

2.1 Center console - remove and install

Removal:

Note

There is no need to remove the selection lever handle and the

dust cover to remove the central console.

– Turn the ignition and all electric consumers off, and remove
the key from ignition.

– Disengage the selector level dust cover.

– Remove fastening screws -1-.
– Disconnect the connector for the 12-volt outlet -U5- or the Cig‐
arette lighter -U1- , if applicable.
– Remove the central console -2-.

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Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -1- to (1.5 Nm) torque.

2.2 Cup holder on seat cushion (Europe only)- assembly overview

1 - Cup holder
2 - Seat framework
3 - Support
4 - Screw
❑ 4 units
❑ 2.5 Nm
5 - Back seat
6 - Lower cup holder lining

2.2.1 Cup holder on seat cushion (exclusive

Europe) - remove and install
Removal:

DANGER!

♦ The folding must be done with access by the side door

and, whenever as possible, by the right side.
♦ Locate the red elastic strap, housed under the seat, and
fit the hook of this strap in the passenger seat's headrest
bar, immobilizing the assembly.

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– Fold the rear seat backrest.

– Remove fastening screws -4-.
– Return rear seat assembly to use position.
– Remove cup holder -1- with the cup holder lower lining -6- from
rear seat cushion -5-.
Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -4- to (2.5 Nm) torque.

2.3 Parking brake lever handle - remove

and install
Removal:

10 Rep. gr.68 - Internal Equipment

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– Pull the parking brake lever handle -2- up.

– Fit a small screwdriver in the lever opening and press against
the handle -arrow A-.
– Remove the handle -1- from the parking brake lever -2- by
pulling towards the front -arrow B-.
Installation:
The installation occurs in the reversal sequence of removal.

2.4 Tray at the passenger's side (instrument

panel without glove compartment) - re‐
move and install
Removal:
– Remove dashboard central frame ⇒ page 12 .
– Remove fan control ⇒ Heating, air conditioning; Rep. gr. 80 ;
Heating .
– Remove screws -1- that fasten the instrument panel and -2-
that fasten cup holder.
– Pull the instrument panel and disengage the tray.
Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -2- to (1.5 Nm) torque.
– Tighten fastening screws -1- to (3.5 Nm) torque.

2.5 Glove compartment (Europe only)

2.5.1 Glove compartment (exclusive Europe)

- remove and install
Removal:
– Remove upper -A- and side -B- screws.
– Remove lower screws -C-.
– Remove glove compartment.
– Release connector on the passenger's airbag deactivation
switch or glove compartment lighting switch, as applicable.
– Remove the glove compartment.
Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -A-, -B- and -C- to (1.5 Nm).

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 Fox 2004 ➤
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2.5.2 Glove compartment cover (exclusive

Europe) - remove and install
Removal:
– Remove the gloves compartment ⇒ page 11 .
– Thread a self-tapping screw into the existing hole in the joint
pin until fastening it to the pin. Then, pull screw -arrow- with a
pliers.
– Remove the joint pin.
Installation:
The installation occurs in the reversal sequence of removal.

2.6 Central frame on the instrument panel

(instrument panel without glove com‐
partment)
Special tools and workshop equipment required
♦ Spatula -VW 037-

♦ Wedge -3409-

2.6.1 Central frame on the instrument panel (instrument panel without glove com‐
partment) - assembly overview

12 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
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1 - Instrument panel (instru‐

ment panel without glove com‐
partment)
❑ Remove and install
⇒ page 74 .
2 - Screw
❑ 2 units.
❑ 1.5 Nm.
3 - Center instruments panel
frame
❑ Remove and install
⇒ page 13 .

2.6.2 Central frame on the instrument panel

(instrument panel without glove com‐
partment) - remove and install
Removal:
– Remove the radio ⇒ Communication; Rep. gr. 91 ; Radio,
telephone, navigation system .
– Remove switches located on central frame -3- ⇒ Electrical
system; Rep. gr. 96 ; Internal switches, lights and lamps,
alarm .

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– Remove fastening screws -2-.

– Disengage and remove central frame from the instrument pan‐
el -3- with the aid of a Spatula -VW 037- or a Wedge -3409- .

Note

Steering wheel is not shown to facilitate visualization of the central

frame removal from the instrument panel, and its removal is not
required.

Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -2- to (1.5 Nm) torque.

2.7 Central frame on instrument panel (with

glove compartment - Europe only)
Special tools and workshop equipment required
♦ Spatula -VW 037-

♦ Wedge -3409-

2.7.1 Central frame on instrument panel (with glove compartment - Europe only)
- assembly overview

14 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
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1 - Instrument panel (with

glove compartment - exclusive
Europe)
❑ Remove and install
⇒ page 77 .
2 - Screw
❑ 4 units.
❑ 1.5 Nm.
3 - Screw
❑ 1 unit.
❑ 1.5 Nm.
4 - Center instruments panel
frame
❑ Remove and install
⇒ page 15 .

2.7.2 Central frame on instrument panel (with

glove compartment - Europe only) - re‐
move and install
Removal:
– Remove the radio ⇒ Communication; Rep. gr. 91 ; Radio,
telephone, navigation system .
– Remove switches located on central frame -4- ⇒ Electrical
system; Rep. gr. 96 ; Internal switches, lights and lamps,
alarm .
– Remove the central console.

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 Fox 2004 ➤
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– Remove fastening screws -2- and -3-.

– Disengage and remove central frame from the instrument pan‐
el -4- with the aid of a Spatula -VW 037- or a Wedge -3409- .
Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -2- and -3- to (1.5 Nm).

2.8 Luggage retaining net

2.8.1 Luggage holding net - assembly overview

1 - Screw
❑ 4 units.
❑ 2 Nm.
2 - Luggage net
❑ Remove and install
⇒ page 17 .
3 - Riveted nut
❑ 4 units.
❑ In order to install it, use
the POP NUT rivet nut
applier -VAG 1765B- or
POP NUT rivet nut ap‐
plier -EQ 7422- .
4 - Lateral lining of the trunk
❑ Remove and install

16 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
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⇒ page 122 .

2.8.2 Luggage holding net - removal and in‐

stallation
Removal:
– Remove fastening screws -1-.
– Unplug and remove the net -2-.
Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -1- to (2 Nm) torque.

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 Fox 2004 ➤
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2.9 Parasol - removal and installation

2.9.1 Assembly overview

1 - Parasol assembly
2 - Screw
❑ 1 unit.
❑ 2 Nm.
3 - Fastening support
4 - Fastening support
❑ In order to remove it,
turn it 90° clockwise.
5 - Screw
❑ 1 unit.
❑ 2 Nm.

2.9.2 Removal

Note

The removal and installation is described for the left parasol.

Right-hand sunshade removal and installation are analogous.

18 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

– Fold and disengage the sun visor -1- from the fastening sup‐
port -4-.
– Remove the fastening screw -5-.
– Turn it „90° clockwise “ and remove the fastening support
-4- .
– Remove fastening screw -2- and remove sunshade -1- with
fastening support -3-.

2.9.3 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -5- with torque of (2 Nm).

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 Fox 2004 ➤
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3 Roof`s Safety Handles

3.1 Roof safety handle - remove and install

Removal:

Note

The removal and installation procedure is described for the left

ceiling safety handle. Removal and installation for the right roof`s
safety handle is made in an analogue manner.

– Fold the safety handle -1- downwards.

– Unplug and turn upwards -arrow- the covers -3-.
– Remove the fastening screws -2- and remove the safety han‐
dle -1-.
Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -2- to (2 Nm) torque.

20 Rep. gr.68 - Internal Equipment

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4 Door sill's trims

Special tools and workshop equipment required
♦ Spatula -VW 037-

♦ Wedge -3409-

4.1 Door sill's trims (2 doors)

Note

The removal and installation is described for the door sill's trim in
the left side. The removal and installation for the right door sill's
trim is made in an analogue manner.

4.1.1 Door sill's trims (2 doors) - assembly overview

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 Fox 2004 ➤
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1 - Door sill's trim

❑ Remove and install
⇒ page 23 .
2 - Front lid's lock activating
lever
❑ Removal and installa‐
tion ⇒ Body - External
assembly works; Rep.
gr. 55 ; Lids .
3 - Screw
❑ 2 units.
❑ 2 Nm.
4 - Side lining
❑ Remove and install
⇒ page 115 .
5 - Clip
❑ Replace it if damaged.

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4.1.2 Door sill's trims (2 doors) - removal and

installation
Removal:
– Remove hood latch release lever -2- ⇒ Body - External as‐
sembly work; Rep. gr. 55 ; Covers .
– Unplug the door sill's trim -1- moving it upwards, starting in the
front part.
– Remove from the side lining -4- of the door sill's trim -1- in the
rear area.

Note

If necessary, use a Spatula -VW 037- or a Wedge -3409- to re‐

move the trim from the door sill-1-.

Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Before assembling the door's sill trim -1-, check the clamps -5-
and, if necessary, replace them.

– Tighten fastening screws -3- to (2 Nm) torque.

4.2 Door sill trims (4 doors)

Note

The removal and installation is described for the door sill's trim in
the left side. The removal and installation for the right door sill's
trim is made in an analogue manner.

4.2.1 Front door sill trim (4 doors) - assembly overview

4. Door sill's trims 23

 Fox 2004 ➤
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1 - Front door sill's trim

❑ Remove and install
⇒ page 24 .
2 - Front lid's lock activating
lever
❑ Removal and installa‐
tion ⇒ Body - External
assembly works; Rep.
gr. 55 ; Lids .
3 - Screw
❑ 2 units.
❑ 2 Nm.
4 - Lower lining of column B
❑ Remove and install
⇒ page 110 .
5 - Clip
❑ Replace it if damaged.

4.2.2 Front door sill trim (4 doors) - remove

and install
Removal:
– Remove hood latch release lever -2- ⇒ Body - External as‐
sembly work; Rep. gr. 55 ; Covers .

24 Rep. gr.68 - Internal Equipment

 Fox 2004 ➤
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– Unplug the front door sill's trim -1- moving it upwards, starting
in the front.
– Remove the front door sill's trim -1-, moving it ahead, unplug‐
ging it from column B's lower lining -4-.

Note

If necessary, use a Spatula -VW 037- or a Wedge -3409- to re‐

move the trim from the door sill-1-.

Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Before assembling the front door's sill trim -1-, check the clamps
-5- and, if necessary, replace them.

– Tighten fastening screws -3- to (2 Nm) torque.

4. Door sill's trims 25

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4.2.3 Rear door sill's trims (4 doors) - assembly overview

1 - Rear door sill trim

❑ Remove and install
⇒ page 26 .
2 - Clip
❑ Replace it if necessary.
3 - Lower lining of column B
❑ Remove and install
⇒ page 110 .
4 - Stop (threaded pin)
❑ Backseat backing stop,
area of column C.
❑ 1 unit.
❑ 12 Nm.
5 - Finishing of column C
❑ Remove and install
⇒ page 114 .

4.2.4 Rear door sill's trims (4 doors) - removal

and installation
Removal:
– Remove the stop (threaded pin) -4- from the backseat backing.

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– Unplug the rear door sill's trim -1-, starting in the front and
moving to the ends.
– In the rear area, move the sill, carefully unplugging it from col‐
umn C lining -5-.
– In the front area, move the sill, carefully unplugging it from
column B lining -3-.
– Remove the rear door sill's trim -1-.

Note

If necessary, use a Spatula -VW 037- or a Wedge -3409- to re‐

move the trim from the door sill-1-.

Installation:
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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 Fox 2004 ➤
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Note

Before assembling the rear door's sill trim -1-, check the clamps
-2- and, if necessary, replace them.

– Remove the stop (threaded pin) -4- from the backseat backing
with torque of (12 Nm)..

28 Rep. gr.68 - Internal Equipment

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69 – Passenger protection
1 safety belts - general information

1.1 Safety measures for belt pre-tensioner

♦ The checking, assembly and repair works must only be per‐
formed by specialized technicians.
♦ The safety belt pre-tensioner components can never be
opened nor repaired. Always use new components (risk of ac‐
cidents).
♦ The safety belt pre-tensioner units that have been subjected
to shocks or that have fallen on the ground can no longer be
installed in the vehicles.
♦ Always replace the mechanically damaged safety belt pre-
tensioner units (deformities, tears).
♦ Storage and transportation must be in compliance with the
legislation on explosive materials.
♦ The elimination of non-triggered old components is made by
dealers or importers.
♦ The triggered safety belt pre-tensioners can be discarded as
scrap.
♦ The belt pre-tensioner unit must be installed immediately after
being removed from the transport package.
♦ No impact drills can be used to disassemble the belt pre-ten‐
sioners.
♦ When the work is interrupted, the belt pre-tensioner unit must
be returned to the transport package.
♦ The belt pre-tensioner unit cannot be left at an unprotected
place.
♦ The belt pre-tensioner unit cannot be handled with lubricant,
cleaning products or other similar substances, nor may it be
exposed to temperatures above 100° C, even temporarily.
♦ The pyrotechnic propelling load has no expiration date, i.e., it
has unlimited, maintenance-free lifetime.

1.2 Belt pre-tensioner - check

• Unwind the belt.
A fault message will be stored in the Airbag fault memory if a
safety belt pre-tensioner has been triggered.
If the safety belt pre-tensioner has been triggered, the entire safe‐
ty belt must be replaced.

1.3 Pre-tensioner units - elimination

The pre-tensioner units with pyrotechnic load not triggered must
be sent, in their original package, for valuation in compliance with
the rules from the respective national legislation! In case of
doubts, please contact the relevant sales centre or the importer.
The pre-tensioners triggered can be eliminated as industrial res‐
idues.

1. safety belts - general information 29

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2 Safety belts - checking

Caution

Whenever an accident happens, it is necessary to carry out a

systematic inspection of the safety belt system! If any other
damage is verified based upon the check points mentioned
ahead, the client should be informed on the need of replacing
the belts.

2.1 Check points

♦ Check the belt ⇒ page 30 .
♦ Check the automatic rewinder (blocking effect) ⇒ page 31 .
♦ Visual inspection of the belt's fastening ⇒ page 32 .
♦ Check of the belt's fastening operation ⇒ page 32 .
♦ Check the inverters and the fastening's tab ⇒ page 32 .
♦ Check of components and fastening points ⇒ page 32 .
♦ Check the automatic rewinder of the abdominal belt.

Note

If the customer does not accept the replacement of the damaged

safety belt, the respective note should be made.

2.1.1 Belt - checking

– Completely remove the belt from the automatic rewinder or
from the regulating tab of the abdominal belt.
– Verify if the belt is dirty and, if necessary, wash it with a neuter
soap solution.
• The safety belt should be completely replaced with the belt's
fastening, if after a vehicle's accident one of the following
damages is found (cut, torn or worn out belt, or, yet torn fabric
threads).
• If in a vehicle that was not in an accident, any of the following
damages is found, it is only necessary to replace the damaged
safety belt.
Possible damages:

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♦ Cut, torn, or worn out belt.

♦ Torn fabric threads in the belt's border.
♦ Burning by cigarettes and similar.

2.1.2 Automatic rewinder (blocking effect) -

checking
The belt's automatic rewinder has two blocking functions:
1- Checking:
The first blocking function is activated when the belt is quickly
pulled from the automatic rewinder (acceleration of the belt's un‐
winding).
– Pull the belt, strongly, out of the automatic rewinder.
If no blocking is found - replace the full safety belt with its fasten‐
ing.
If there are fails unwinding and winding the belt, it is necessary to
check first if the automatic rewinder position is changed.
2- Checking:
The second locking function operates when a sudden change is
noticed in the vehicle movement (vehicle-dependent locking func‐
tion).
– Fasten the safety belt.
– Accelerate the vehicle until reaching the (20 km/h) speed and
press the brake pedal strongly.
If, during braking, the blocking system does not work, it is neces‐
sary to replace the full safety belt with the fastening.

Caution

For safety reasons, the test drive should be made in a street

without movement, in order not to expose other drivers to the
danger.

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2.1.3 Visual inspection of the belt's fastening .

– Verify the fastening for the formation of tearing and cracks.
• If no blocking is found - replace the full safety belt with its fas‐
tening.

2.1.4 Check of the belt's fastening operation .

Check the belt's fastening:
– Insert the tab in the fastening until hearing its engaging. Check
that the fastening device is engaged, pulling the belt strongly.
• Make at least 5 checking sequences. If, the fastening tab does
not work even if for a single time, replace the full safety belt
with the fastening.
Verify the unlocking:
– Release the safety belt, pressing the respective button with
your finger.
• The latch tab must spring out of the latch automatically as soon
as the belt is released.
• Make at least 5 checking sequences. If, the fastening tab is
not release even if for a single time, the full safety belt with the
fastening should be replaced.

Caution

Never use lubricants to eliminate any kind of noises or lack of

mobility of the safety belt's fastening button.

2.1.5 Guides and latch tab - check

The plastic-coated inverters have thin parallel grooves after a load
stress (belt used in the moment of an accident) is exerted on the
belt's system. (The wearing that results from frequent use is iden‐
tified through plain wearing marks without scratches).
– Check for deformations, cracks or formation of tears in the
plastic.
• When there is the formation of grooves and/or damages, it is
necessary to replace the full safety belt with the fastening.

2.1.6 Components and fastening points -

checking
♦ Deformed fastening strap (elongated).
♦ Height regulation does not work.
♦ Fastening points (seat, support, vehicle's floor) off-center or
with damaged thread.
• If damage is found in the parts, the safety belt should be fully
replaced with its fastening.
• Replace the fastening points.

Note

In the case of damages that are not result of an accident, such as

in case of wearing, it is necessary to replace only the damaged
component.

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2.2 Mooring points of the children's seat

(ISOFIX) - checking after accidents
The mooring points of the children's seat (ISOFIX) are installed
in the structure assembly of the seat/rest of the backseat.
Always check the state of mooring points -1- after an accident.

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3 Front safety belts

3.1 Front seat belt „2-door“ (with pre-tensioner) - assembly overview

1 - Electric harness of the belt

latch
2 - Belt's fastening assembly
❑ Remove and install
⇒ page 43 .
3 - Screw
❑ 1 unit.
❑ 40 Nm.
4 - Screw
❑ 1 unit.
❑ 40 Nm.
5 - Safety belt assembly.
❑ Remove and install
⇒ page 35 .
6 - Screw
❑ 1 unit.
❑ 40 Nm.
7 - Cover cap
8 - Washer
9 - Distance bushing
10 - Screw
❑ 1 unit.
❑ 40 Nm.
11 - Pre-tensioner harness
connector
12 - Connector fastening clip
13 - Seat belt inertia reel with
pre-tensioner

WARNING
The disposal of used
parts that were not trig‐
gered (pre-tensioners) is
carried out by the deal‐
ers or importers
⇒ page 29 .

14 - Safety belt guide

15 - B pillar lining
16 - Screw
❑ 2 units.
❑ 3.5 Nm.

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17 - Belt's height regulator

❑ Remove and install ⇒ page 41 .
18 - Screw
❑ 2 units.
❑ 23 Nm.
19 - Belt guide

3.2 Front seat belt „2-door“ (with pre-ten‐

sioner) - remove and install

Note

The removal and installation is described for the left safety belt.
The removal and installation for the right safety belt is made in an
analogue manner.

WARNING

Before starting any body repair, remove the pre-tensioner units

from the safety belts.
Disconnect the battery earth strap, since the seat belts are
equipped with pre-tensioners.
Before making any work in the electric system, it is necessary
to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

3.2.1 Removal
– Remove the cover cap -7- and the lower fastening screw -6-
of the seat belt ⇒ page 42 .
– Remove the rear side lining ⇒ page 115 .

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– Disconnect the pre-tensioner electric harness -11- and disen‐

gage the connector from the internal panel.
– Fold the belt guide cover cap -19- upwards.
– Remove the fastening screw -4-.
– Remove the director -19-.
– Remove the fastening screws -16- from the safety belt guide
-14-.
– Remove the fastening screw -10-.
– Remove seat belt inertia reel with pre-tensioner -13- on B pil‐
lar.

3.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -10- with torque of (40 Nm).
– Screw on the fastening screws -16- from the safety belt guide
-14- with torque of (3.5 Nm).
– Screw on the fastening screw -4- with torque of (40 Nm).
– Install the belt's lower fastening point and screw on the fas‐
tening screw -6- with torque of (40 Nm) ⇒ page 42 .

3.3 Front seat belt „2-door“ (without pre-tensioner) - assembly overview

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1 - Internal panel of column B

2 - Column B upper lining
❑ Remove and install
⇒ page 106 .
3 - Distance bushing
4 - Belt guide
5 - Screw
❑ 1 unit.
❑ 40 Nm.
6 - Guide cover
❑ Detachable type: Pull it
and remove it, removing
it from the belt guide.
❑ Folding type: Unlock the
lower part and lift it.
7 - Safety belt assembly.
❑ Remove and install
⇒ page 38 .
8 - Screw
❑ 1 unit.
❑ 40 Nm.
9 - Cover cap
10 - Washer
11 - Distance bushing
12 - Screw
❑ 1 unit.
❑ 40 Nm.
13 - Screw
❑ 1 unit.
❑ 40 Nm.
14 - Belt's fastening assembly
❑ Remove and install ⇒ page 43 .
15 - Front seat bottom structure
16 - Safety belt rewinder
17 - Screw
❑ 2 units.
❑ 3.5 Nm.
18 - Safety belt guide
19 - Belt's height regulator
❑ Remove and install ⇒ page 41 .
20 - Screw
❑ 2 units.
❑ 23 Nm.

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3.4 Front seat belt „2-door“ (without pre-ten‐

sioner) - remove and install

Note

The removal and installation is described for the left safety belt.
The removal and installation for the right safety belt is made in an
analogue manner.

3.4.1 Removal
– Remove the lower fastening screw of seat belt -8-
⇒ page 42 .
– Remove the rear side lining ⇒ page 115 .
– Remove or fold the guide cover's cap -6-.
– Remove the fastening screw -5-.
– Remove the belt guide -4- with the distance bushing -3-.
– Remove the fastening screws -17- from the safety belt guide
-18-.
– Remove the fastening screw -12-.
– Remove the safety belt rewinder -16- from column B.

3.4.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -12- with torque of (40 Nm).
– Screw on the fastening screws -17- from the safety belt guide
-18- with torque of (3.5 Nm).
– Screw on the fastening screw -5- with torque of (40 Nm).
– Install the belt's lower fastening point and screw on the fas‐
tening screw -8- with torque of (40 Nm) ⇒ page 42 .

3.5 Front seat belt „4-door“ (without pre-tensioner) - assembly overview

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1 - Internal panel of column B

2 - Column B upper lining
❑ Remove and install
⇒ page 107 .
3 - Distance bushing
4 - Belt guide
5 - Screw
❑ 1 unit.
❑ 40 Nm.
6 - Guide cover
❑ Detachable type: Pull it
and remove it, removing
it from the belt guide.
❑ Folding type: Unlock the
lower part and lift it.
7 - Safety belt assembly.
❑ Remove and install
⇒ page 40 .
8 - Screw
❑ 1 unit.
❑ 40 Nm.
9 - Screw
❑ 1 unit.
❑ 40 Nm.
10 - Safety belt rewinder
11 - Positioning lever
❑ The angle -A- should be
of„ 27° “.
❑ The -arrow- indicates
the front of the vehicle.
12 - Screw
❑ 1 unit.
❑ 40 Nm.
13 - Belt's fastening assembly
❑ Remove and install ⇒ page 43 .
14 - Front seat bottom structure
15 - Screw
❑ 2 units.
❑ 3.5 Nm.
16 - Safety belt guide
17 - Belt's height regulator
❑ Remove and install ⇒ page 41 .
18 - Screw
❑ 2 units.
❑ 23 Nm.

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3.6 Front seat belt „4-door“ (without pre-ten‐

sioner) - remove and install

Note

The removal and installation is described for the left safety belt.
The removal and installation for the right safety belt is made in an
analogue manner.

3.6.1 Removal
– Remove the lower fastening screw of seat belt -8-
⇒ page 42 .
– Remove the lower lining of column B ⇒ page 110 .
– Remove or fold the guide cover -6-.
– Remove the fastening screw -5-.
– Remove the belt guide -4- with the distance bushing -3-.
– Remove the fastening screws -15- from the safety belt guide
-16-.
– Remove the fastening screw -9-.
– Remove the safety belt rewinder -10- from column B.

3.6.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -9- with torque of (40 Nm).
– Screw on the fastening screws -15- from the safety belt guide
-16- with torque of (3.5 Nm).
– Screw on the fastening screw -5- with torque of (40 Nm).

Note

♦ During the installation of the position lever -11- observe the

correct assembly angle-A-.
♦ The angle -A- should be of„ 27° “.
♦ The -arrow- indicates the front of the vehicle.

– Install the belt's lower fastening point and screw on the fas‐
tening screw -8- with torque of (40 Nm) ⇒ page 42 .

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3.7 Belt height adjustment „2 and 4-door“ -

remove and install

Note

The removal and installation is described for the right belt height
regulator. The removal and installation for the left belt height reg‐
ulator is made in an analogue manner.

3.7.1 Removal
2-door vehicles:
– Remove the belt guide -4- ⇒ page 36 .
– Remove the upper lining of column B -2- ⇒ page 106 .
4-door vehicles:
– Remove the belt guide -4- ⇒ page 38 .
– Remove the upper lining of column B -2- ⇒ page 108 .
Continues for 2 and 4 door vehicles:
– Remove fastening screws -1-.
– Remove the belt height regulator -2- from column B.

3.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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– Tighten fastening screws -1- to (23 Nm) torque.

3.8 Fastening point of the front belt - remov‐

al and installation

Note

The removal and installation is described for the left belt fastening
point. The removal and installation for the left belt fastening point
is made in an analogue manner.

3.8.1 Removal
– Unplug the cover cap -2- of the fastening screw -1-.
– Remove the fastening screw -1-.
– Remove the belt's lower fastening point -3- with the distance
bushing -4-.

3.8.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -1- with torque of (40 Nm).

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3.9 Front seat belt latch (Europe only) - re‐

move and install

3.9.1 Removal
Left front seat (driver)
– Remove the seat ⇒ page 146 .

Note

The seat must be adjusted to its mid height (seat height adjust‐
ment).

– Remove the belt latch connector -1- (press side locks).

– Remove clips -2- and -3-.
– Remove seat belt harness -4-.

– Remove the fastening screw -2-.

– Remove seat belt latch -3- along with the seat belt har‐
ness-1-.
Right front seat (passenger).
– Fully move the seat back.

– Remove the fastening screw -1-.

– Remove the belt fastening -2-.

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3.9.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
Left front seat (driver)
– Install the belt latch -3-.
– Screw on the fastening screw -2- with torque of (40 Nm).
– Install belt latch harness -1- by observing the location indica‐
ted in the illustration.

– Connect the connector -1-.

– Fasten clips -2- and -3- by passing the belt latch harness -4-
through its respective clips.
Right front seat (passenger).

– Install the belt latch -2-.

– Screw on the fastening screw -1- with torque of (40 Nm).

3.10 Fastening of the front belt - removal and

installation

Note

The removal and installation is described for the left safety belt
fastening. The removal and installation for the right safety belt
fastening is made in an analogue manner.

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3.10.1 Removal
– Fully move the seat back.
– Remove the fastening screw -1-.
– Remove the belt fastening -2-.

3.10.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -1- with torque of (40 Nm).

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4 Rear safety belts

4.1 Rear seat belt (with automatic inertia reel) - assembly overview

1 - Distance bushing
2 - Belt guide
3 - Screw
❑ 1 unit.
❑ 40 Nm.
4 - Seat belt's inertia reel
5 - Screw
❑ 1 unit.
❑ 40 Nm.
6 - Double fastening assembly
❑ Remove and install
⇒ page 50 .
7 - Nut
❑ 4 units.
❑ 30 Nm.
8 - Lap belt and latch assembly
❑ Remove and install
⇒ page 50 .
9 - Belt tab
10 - Belt's lower fastening point
❑ Remove and install
⇒ page 49 .
11 - Screw
❑ 1 unit.
❑ 40 Nm.

4.2 External rear seat belt (with automatic

inertia reel) - remove and install

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.2.1 Removal
Vehicles (2 doors):
– Remove the lining of column C ⇒ page 111 .
– Remove the side lining ⇒ page 115 .

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– Remove the belt's lower fastening point, rear area

⇒ page 49 .
Vehicles (4 doors):
– Remove the lining of column C ⇒ page 114 .
– Remove the rear door sill's trim ⇒ page 26 .
– Remove the belt's lower fastening point, rear area
⇒ page 49 .
Continues for vehicles (2 and 4 doors):
– Remove the fastening screw -5-.
– Remove belt guide -2- with the spacer bushing -1-.
– Remove the fastening screw -4-.
– Remove the seat belt inertia reel -3-.

4.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -4- with torque of (40 Nm).
– Screw on the fastening screw -5- with torque of (40 Nm).
– Install the belt's lower fastening point, rear area, screwing on
the fastening screw with torque of (40 Nm) ⇒ page 49 .

4.3 Rear seat belts (without automatic inertia reels) - assembly overview

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1 - Belt's upper fastening point

2 - Screw
❑ 1 unit.
❑ 40 Nm.
3 - Double fastening assembly
❑ Remove and install
⇒ page 50 .
4 - Nut
❑ 4 units.
❑ 30 Nm.
5 - Abdominal belt with simple
fastening
❑ Remove and install
⇒ page 50 .
6 - Belt tab
7 - Belt's lower fastening point
❑ Remove and install
⇒ page 49 .
8 - Screw
❑ 1 unit.
❑ 40 Nm.

4.4 External rear seat belts (without auto‐

matic inertia reels) - remove and install

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.4.1 Removal
Vehicles (2 doors):
– Remove the lining of column C ⇒ page 111 .
– Remove the side lining ⇒ page 115 .
– Remove the belt's lower fastening point, rear area
⇒ page 49 .
Vehicles (4 doors):
– Remove the lining of column C ⇒ page 114 .
– Remove the rear door sill's trim ⇒ page 26 .

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– Remove the belt's lower fastening point, rear area

⇒ page 49 .
Continues for vehicles (2 and 4 doors):
– Remove the fastening screw -1-.
– Remove the safety belt fastening point -2-.

4.4.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -1- with torque of (40 Nm).
– Install the belt's lower fastening point, rear area, screwing on
the fastening screw with torque of (40 Nm) ⇒ page 49 .

4.5 Lower fastening point of the rear belt -

removal and installation

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.5.1 Removal
Vehicles (2 doors):
– Remove the side lining ⇒ page 115 .

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Vehicles (4 doors):
– Remove the rear door sill's trim ⇒ page 26 .
Continues for vehicles (2 and 4 doors):
– Remove the fastening screw -1-.
– Remove the lower fastening point of seat belt -2-.

4.5.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Screw on the fastening screw -1- with torque of (40 Nm).

4.6 Lap belt with dual latch „2 and 4-

door“ (rear seat without longitudinal ad‐
justment) - remove and install

4.6.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's lining and stuffing ⇒ page 199 .

Note

The lining do not need to be removed from the stuffing.

Abdominal safety belt with simple fastening and double fasten‐

ings:

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– Remove belt fastening nuts -1-(2 units) on the hinges -2-.

Safety belt fasteners:

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– Remove the fastening screws -1- of the belt in the seat struc‐
ture -2-.

4.6.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
Abdominal safety belt with simple fastening and double fasten‐
ings:

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– Fasten the fastening nuts -1- of the belt in the hinges -2- with
torque of (40 Nm) .
Safety belt fasteners:

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– Fasten the fastening screws -1- of the belt in the seat structure
-2- with torque of (40 Nm) .

4.7 Lap belt with dual latch „2 and 4-

door“ (rear seat with longitudinal adjust‐
ment) - remove and install

4.7.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's lining and stuffing ⇒ page 199 .

Note

The lining do not need to be removed from the stuffing.

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Abdominal safety belt with simple fastening and double fasten‐

ings:
– Remove the fastening nuts -6- from the seat structure assem‐
bly -1- and from the seat's rail -4-.
– Remove the abdominal safety belt with simple fastening -5-
and the double fastenings -2- from their respective studs -5-,
located in the structure of the seat rail -4-.

4.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install the abdominal safety belt with simple fastening -5- and
the double fastenings -2- to its respective studs -3-, located in
the seat rail's structure -4-.
– Install the seat rail's structure assembly -4- to the seat struc‐
ture assembly -1- and fasten the fastening nuts -6- with torque
of (30 Nm).

4.8 Single latch„2-door“ (split rear set with

longitudinal adjustment - Europe only) -
remove and install

4.8.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's lining and stuffing ⇒ page 199 .

Note

The lining do not need to be removed from the stuffing.

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Safety belt fasteners:

– Remove the fastening nuts -6- from the seat structure assem‐
bly -1- and from the seat's rail -4-.
– Remove lap belt latches -2- and -5- from their respective studs
-3- located on the seat rail structure -4-.

4.8.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install seat belt latches -2- and -5- on their respective studs
-3- located on the seat rail structure -4-.
– Install the seat rail's structure assembly -4- to the seat struc‐
ture assembly -1- and fasten the fastening nuts -6- with torque
of (30 Nm).

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5 Airbag

5.1 Installation locations - assembly overview

1 - Airbag control lamp -K75-

❑ Located in the com‐
bined Instrument -K- .
2 - Trigger for driver's airbag -
N95-
❑ Remove and install 3-
spoke steering wheel
⇒ page 59
❑ Remove and install 4-
spoke steering wheel
⇒ page 61
3 - Trigger 1 for front passen‐
ger airbag -N131-
❑ Remove and install
⇒ page 65 .
❑ Adjusting components
(blocking and activat‐
ing) ⇒ page 73 .
4 - Driver/passenger side air‐
bag trigger -N199 / N200-
❑ Remove and install
⇒ page 67 .
5 - Airbag control unit -J234-
❑ Remove and install
⇒ page 69 .
❑ Adapting components
(encoding)
⇒ page 72 .
6 - Diagnostics connector
❑ Located in the fuse com‐
partment below the
steering column.

5.2 Safety measures for working with Air‐

bags

WARNING

Before carrying out any repairs on the Airbag, disconnect the

battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Starter
motor, alternator, battery .
Once the battery's earth strap is disconnected, the repairs can
be conducted immediately.
No-one should remain inside the vehicle during the battery's
earth strap connection.

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Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

♦ The checking, assembly and repair should only be made by

specialized personnel.
♦ Before handling (touching) the airbag ignition device, the me‐
chanical should unload his body's electrostatic charge. This is
made by touching grounded metallic pieces, such as: water
pipes, heating tubes or metallic beams.
♦ The airbag ignition device installation should be made imme‐
diately after they are removed from its shipping package.
♦ When the work is interrupted, the airbag ignition device should
be returned to its shipping package.
♦ It is forbidden leaving the airbag ignition devices in a place
without care.
♦ The removed airbag ignition devices should be stored so that
the cushioned side be turned upwards.
♦ The airbag ignition devices that fall on a hard surface or
present damages cannot be installed again.
♦ The airbag ignition device that were not fired should be iden‐
tified and returned to the manufacturer to be eliminated (use
the airbag ignition devices shipping package).
♦ The storage and shipping should be in compliance with the
legislation for explosive materials.

5.3 Airbag ignition devices after an accident

- replacing

5.3.1 Accident with airbag firing

The following components should always be replaced:
♦ All the fired airbag ignition devices with their command units
and sensors.
♦ Supports of the Ignition device 1 for the front passenger airbag
-N131- .
♦ Airbag coil connector and return spring with sliding ring -
F138- .
Visual inspection - replace it if necessary:
♦ All the damaged components.

Note

After the repair, even if the airbag control lamp -K75- do not indi‐
cate any failure, the record of defects regarding airbag compo‐
nents should be verified with the help of the Diagnosis, Measuring
and Information System -VAS 5051A/52- ⇒ page 72 .

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5.3.2 Accident without airbag firing

Note

Even if the airbag control lamp -K75- does not indicate any failure,
the airbag component damage memory must be checked, using
the Diagnosis, Measurement, and Information System -VAS
5051A/52- ⇒ page 72 .

Items that should be checked:

♦ Airbag control lamp -K75-
♦ Trigger for driver's airbag -N95-
♦ Trigger 1 for front passenger airbag -N131-
♦ Driver/passenger side airbag trigger -N199 / N200-
♦ Airbag control unit -J234-
♦ Safety belts front and rear, as well as the mooring points of the
children's seat (ISOFIX) ⇒ page 30 .

5.4 Ignition device for driver's airbag -N95-

(steering wheel with 3 spokes) - removal
and installation

Caution

Observe the safety measures to work with the Airbag

⇒ page 57 .

WARNING

Before working on the electrical system, it is necessary to dis‐

connect the battery earth strap. ⇒ Electrical equipment; Rep.
gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

5.4.1 Removal
– Pull the steering column out completely and lock it in the lower
position.
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

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Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Turn the steering wheel to the position shown in the figure (90°
left).

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Fit a screwdriver, about 5 mm in width, from behind, to the

steering wheel protective hole.
– Press the screwdriver upwards -arrow- until locking spring
-1- is unlocked and the Ignition device for the driver's airbag -
N95- disengages partially from the steering wheel housing.
– Turn the steering wheel to (180° right) and unlock the second
locking.

– Carefully remove the Driver's airbag ignition device -N95- ,

pulling it a little a little away from the steering wheel.

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the vehicle's door lock stop.

– Carefully detach the lock -1- from the connector -2- with a
screwdriver.
– Disconnect connector -2- and remove the trigger for the driv‐
er's airbag -N95- .

5.4.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the vehicle's door lock stop.

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– Insert connector -2- in the Ignition device for driver's airbag -

N95- and lock it with lock -1-.
– Place the ignition device for the driver's airbag -N95- in the
installation position and press it inwards to the steering wheel
until the engaging is heard in both sides.
Assembly notes:
♦ Turn off all electrical devices.
♦ Turn on the ignition.
♦ Connect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

5.5 Ignition device for driver's airbag -N95-

(steering wheel with 4 spokes) - removal
and installation

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

5.5.1 Assembly overview:

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1 - Steering wheel
❑ Remove and install ⇒
Chassis, axles, steer‐
ing; Rep. gr. 48 ; Steer‐
ing .
2 - Connector of Ignition device
for driver's airbag -N95-
3 - Trigger for driver's airbag -
N95-
❑ Remove and install
⇒ page 62 .

5.5.2 Removal
– Pull the steering column out completely and lock it in the lower
position.
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

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– Turn the steering wheel until the horizontal spokes are in ver‐
tical position (left 90°).
– Fit a screwdriver, about 5 mm in width, from behind, to the
steering wheel protective hole.
– Press the screwdriver upwards -arrow- until locking spring is
unlocked and the Ignition device for the driver's airbag -N95-
disengages partially from the steering wheel housing.
Turn the steering wheel to (180° right) and unlock the second
locking.
– Carefully remove the Driver's airbag ignition device -N95- ,
pulling it a little a little away from the steering wheel.

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the vehicle's door lock stop.

– Carefully detach the lock -1- from the connector -2- with a
screwdriver.
– Disconnect connector -1- and remove the trigger for the driv‐
er's airbag -N95- .

5.5.3 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the vehicle's door lock stop.

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– Engage and lock connector -2- on the Ignition device for the
driver's airbag -N95- -3-.
– Place the Ignition device for the driver's airbag -N95- -3- in the
installation position and insert it into the steering wheel, press‐
ing it until a click is heard on both sides.
Assembly notes:
♦ Turn off all electrical devices.
♦ Turn on the ignition.
♦ Connect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

5.6 Connector of the airbag coil and return

spring with sliding ring -F138- - remove
and install

5.6.1 Removal
Vehicles with (3 spokes steering wheel):
– Remove the Ignition device for driver's airbag -N95- (3-spoke
steering wheel) ⇒ page 59 .
– Remove steering wheel (3-spoke steering wheel) ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering .
Vehicles with (4 spokes steering wheel):
– Remove the Ignition device for driver's airbag -N95- (4-spoke
steering wheel) ⇒ page 61 .
– Remove steering wheel (4-spoke steering wheel) ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering .
Continues for vehicles with (3- and 4-spoke steering wheel):
– Remove the steering column covering ⇒ page 87 .

Note

In the removal and installation of the Airbag coil connector and

return spring with sliding ring -F138- it is necessary to pay atten‐
tion for the connector to be in intermediate position (wheels ahead
- Aligned).

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– Disconnect the connector -1-.

– Disengage the coupling hook -2- from the Airbag coil connec‐
tor and return spring with sliding ring -F138- and remove it.

5.6.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

In the removal and installation of the Airbag coil connector and

return spring with sliding ring -F138- it is necessary to pay atten‐
tion for the connector to be in intermediate position (wheels ahead
- Aligned).

5.7 Trigger 1 for front passenger's airbag -

N131- - remove and install

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

5.7.1 Removal
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .
– Remove the instrument panel ⇒ page 74 .

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Caution

Observe the safety measures to work with the Airbag

⇒ page 57 .

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the vehicle's door lock stop.

– Disconnect the connector -3-.

– Remove fastening screws -2-.
– Remove the Ignition device 1 for front passenger's airbag -
N131- -1- from the support.

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5.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install the Ignition device 1 for front passenger's airbag -N131-
-1- on the support.
– Insert fastening screws -2- in position and tighten as minimum
as possible.
– Tighten screw -A- to preliminary torque.
– Turn Ignition device 1 for front passenger's airbag -N131-
clockwise -arrow C- to stop of screw -B-.
– Tighten fastening screw -B- to (10 Nm).
– Tighten fastening screw -A- to (10 Nm).
– Tighten other fastening screws-2- to (10 Nm).
– Connect the connector -3-.
Assembly notes:
♦ Turn off all electrical devices.
♦ Turn on the ignition.
♦ Connect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

5.8 Driver's/passenger's side airbag trigger

-N199 / N200- - remove and install

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

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5.8.1 Removal

Note

The removal and installation is described for the front left seat.
The removal and installation for the front right seat is made in an
analogue manner.

– Turn ignition off.

– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Remove the front seat ⇒ page 146 .

– Remove the front seat backing ⇒ page 158 .
– Remove the seat backrest lining ⇒ page 192 .
– Release and pass connector -2- through the opening in the
backrest lining.

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the vehicle's door lock stop.

– Remove fastening screws -3-.

– Remove the Driver's/passenger's side airbag trigger -N199 /
N200- -4- from the seat backrest frame -1-.

5.8.2 Installation
– Installation is carried out by reversing the removal order, con‐
sidering the following:

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– Pass the connector -2- through the opening in the seat back‐
rest lining and engage it.
– Install the Driver's/passenger's side airbag trigger -N199 /
N200- -4- on the seat backrest frame -1-.
– Tighten fastening screws -3- to (7 Nm) torque.
– Install the front seat ⇒ page 146 .
Assembly notes:
♦ Turn off all electrical devices.
♦ Turn on the ignition.
♦ Close vehicle doors.
♦ Connect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

5.9 Control unit for the airbag -J234- - re‐

moval and installation

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

5.9.1 Removal
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

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Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Remove the center console ⇒ page 8 .

– Turn locking handle -2- towards arrow and disengage con‐
nector -3- from the Airbag control unit -J234- -1-.
– Remove nuts -4- .
– Remove the Airbag control unit -J234- -1- from studs.

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the door lock stop.

5.9.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Place the Airbag control unit -J234- -1- on studs.
– Tighten the nuts -4- with (9 Nm) of torque.
Assembly notes:
♦ Turn off all electrical devices.
♦ Turn on the ignition.
♦ Connect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

Note

If the Control unit for the airbag -J234- was replaced, it should be
encoded; adapt (encode) the components ⇒ page 72 .

5.10 Passenger's side airbag crash sensor -

G180- and Driver's side airbag crash
sensor -G179- - remove and install

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

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WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

5.10.1 Removal

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

– Turn ignition off.

– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Remove the front seat ⇒ page 146 .

– Remove the front door sill trim ⇒ page 21 .
– Disengage the floor covering in the sensor region.
– Disengage connector -1- of Passenger's side airbag crash
sensor -G180- or Driver's side airbag crash sensor -G179- .
– Remove fastening screws -2-.
– Remove the Passenger's side airbag crash sensor -G180- or
Driver's side airbag crash sensor -G179-

Caution

The electrostatic discharges can cause an involuntary firing of

the airbag. That's why the assembler should perform the elec‐
trostatic discharging before connecting the ignition cable and
the mass cable. This can be done, for instance, by touching
the door lock stop.

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5.10.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install the Passenger's side airbag crash sensor -G180- or
Driver's side airbag crash sensor -G179-
– Tighten fastening screws -2- to (9 Nm) torque.
– Connect the connector -1- of Passenger's side airbag crash
sensor -G180- or Driver's side airbag crash sensor -G179- .
Assembly notes:
♦ Turn off all electrical devices.
♦ Turn on the ignition.
♦ Connect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

5.11 Components - adapting/verifying

Special tools and workshop equipment required
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-

♦ Diagnosis cable -VAS 5051/1- , -VAS 5051/5A- , -VAS 5051/3-

or -VAS 5051/6B-

5.11.1 Work sequence

– Connect the Diagnosis, Measurement, and Information Sys‐
tem -VAS 5051A/52- to the 16-pin diagnosis connector -T16-
located on the fuse compartment, below the steering column.
⇒ General information; Rep. gr. 97 ; Electrical cables and
harnesses
– Turn on the ignition.
– Turn off all electrical devices.
– Proceed by selecting the desired functions ⇒ Vehicle diag‐
nostic tester.

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6 Deactivation of the airbag

6.1 Ignition device 1 for the front passenger

airbag -N131- - blocking or activation

WARNING

The previous conditions for deactivation (decommissioning) of

one or more airbag units are published in the „Service Manual
- Technique“.

In the „Service Manual - Technique 2“, the „process ID “ or the

„TPL Number“ for deactivation of airbag units is: „2010201“.
ElsaWin:
→ Solving technical problems.
→ Service Manual - Technical.
→ Solving technical problems.
→Electrical system
→ Function.
→ Passenger protection.
→ Deactivation of airbag units.
→ Systems.

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70 – Finishing/insulation
1 Instrument panel

1.1 Tools
Special tools and workshop equipment required
♦ Spatula -VW 037-

♦ Wedge -3409-

♦ Ejecting lever -80-200- .

1.2 Instrument panel - remove and install

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

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Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

1.2.1 Removal
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .
– Remove the Ignition device for the driver's airbag -N95- .
Vehicles with (3 spokes steering wheel): ⇒ page 59 .
Vehicles with (4 spokes steering wheel): ⇒ page 61 .

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Remove the steering wheel ⇒ Chassis, axles, steering; Rep.

gr. 48 ; Steering .
– Remove the steering column covering (without adjustment)
⇒ page 87 .
– Remove the Airbag coil connector and return spring with slid‐
ing ring -F138-
– Remove the turn signal and wiper/washer switches⇒ Electri‐
cal system; Rep. gr. 94 ; Switches, lights, and external lamps .
– Remove A pillar coverings (right and left side) ⇒ page 104 .
– Remove side air baffles -1- ⇒ Heating, air conditioning; Rep.
gr. 80 ; Heating .
– Remove the radio ⇒ Communication; Rep. gr. 91 ; Radio,
telephone, navigation system .
– Remove the central frame on instrument panel -2-
⇒ page 12 .
– Remove ventilation adjustment mechanism -3- ⇒ Heating, air
conditioning; Rep. gr. 80 ; Heating .
– Remove fuse support -4- ⇒ Electrical equipment; Rep. gr. 97 ;
Electrical cables and harnesses .

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– Remove fastening screws -9- and disengage upper cover on

instrument panel -8- with central air baffles ⇒ Heating, air
conditioning; Rep. gr. 80 ; Heating .
– Remove the Combined instrument -K- ⇒ Electrical system;
Rep. gr. 90 ; Instrument case, indicators .
– Remove the steering column covering (with adjustment)
⇒ page 89 .
– Remove fastening screws -7-.
– Remove fastening bolts -6- from the Ignition device 1 for front
passenger's airbag -N131- .

– Remove fastening screws -11-.

– Remove the fastening screws -12-, -13-, -14- and -15-.
– Position the wire harnesses inwards the instruments panel
-10- to make the removal easier.
– Remove the instrument panel -10-.

Note

To unplug and remove the instruments panel -10-, it is recom‐

mended the help of a second operator.

1.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Help from a second operator is recommended to install the in‐

strument panel -10-.

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Note

♦ Observe tightening sequence of fastening screws on instru‐

ment panel -10-.
♦ Tighten fastening screws -11- to (1.5 Nm) torque.
♦ Tighten fastening screws -15- to (3.5 Nm) torque.
♦ Tighten fastening screws -13- to (3.5 Nm) torque.
♦ Tighten fastening screws -12- to (3.5 Nm) torque.
♦ Tighten fastening screws -14- to (3.5 Nm) torque.

– Tighten fastening bolts -6- on Ignition device 1 for front pas‐

senger's airbag -N131- to (10 Nm).
– Tighten fastening screws -7- to (1.5 Nm) torque.
– Install the steering column covering (with adjustment)
⇒ page 89 .
– Engage the upper cover on instrument panel -8- with central
air baffles and tighten screws -9- with (1.5 Nm) ⇒ Heating, air
conditioning; Rep. gr. 80 ; Heating .

1.3 Instrument panel (with glove compart‐

ment - exclusive Europe) - remove and
install

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

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1.3.1 Removal
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .
– Remove the Ignition device for the driver's airbag -N95- .
Vehicles with (3 spokes steering wheel): ⇒ page 59 .
Vehicles with (4 spokes steering wheel): ⇒ page 61 .

Caution

Observe the safety measures to work with the Airbag .

⇒ page 57

– Remove the steering wheel ⇒ Chassis, axles, steering; Rep.

gr. 48 ; Steering .
– Remove the Airbag coil connector and return spring with slid‐
ing ring -F138-
– Remove the steering column covering (without adjustment)
⇒ page 87 .
– Remove the turn signal and wiper/washer switches⇒ Electri‐
cal system; Rep. gr. 94 ; Switches, lights, and external lamps .
– Remove A pillar coverings (right and left side) ⇒ page 104 .
– Remove side air baffles -1- ⇒ Heating, air conditioning; Rep.
gr. 80 ; Heating .
– Remove the radio ⇒ Communication; Rep. gr. 91 ; Radio,
telephone, navigation system .
– Remove the center console ⇒ page 8 .
– Remove the central frame on instrument panel -2-
⇒ page 14 .
– Remove ventilation adjustment mechanism -3- ⇒ Heating, air
conditioning; Rep. gr. 80 ; Heating .
– Remove fuse support -4- ⇒ Electrical equipment; Rep. gr. 97 ;
Electrical cables and harnesses .

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– Remove fastening screws -8- and disengage upper cover on

instrument panel -7- with central air baffles ⇒ Heating, air
conditioning; Rep. gr. 80 ; Heating .
– Remove the Combined instrument -K- ⇒ Electrical system;
Rep. gr. 90 ; Instrument case, indicators .
– Remove the steering column covering (with adjustment)
⇒ page 89 .
– Remove fastening screws -6-.
– Remove fastening bolts -5- from the Ignition device 1 for front
passenger's airbag -N131- .

– Remove fastening screws -10-.

– Remove the fastening screws -11-, -12-, -13- and -14-.
– Position the wire harnesses inwards the instruments panel
-9- to make the removal easier.
– Remove the instrument panel -9-.

Note

To unplug and remove the instruments panel -9-, it is recommen‐

ded the help of a second operator.

1.3.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Help from a second operator is recommended to install the in‐

strument panel -9-.

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Note

♦ Observe tightening sequence of fastening screws on instru‐

ment panel -9-.
♦ Tighten fastening screws -10- to (1.5 Nm) torque.
♦ Tighten fastening screws -14- to (3.5 Nm) torque.
♦ Tighten fastening screws -12- to (3.5 Nm) torque.
♦ Tighten fastening screws -11- to (3.5 Nm) torque.
♦ Tighten fastening screws -13- to (3.5 Nm) torque.

– Tighten fastening bolts -5- on Ignition device 1 for front pas‐

senger's airbag -N131- to (10 Nm).
– Tighten fastening screws -6- to (1.5 Nm) torque.
– Install the steering column covering (with adjustment)
⇒ page 89 .
– Engage the upper cover on instrument panel -7- with central
air baffles and tighten screws -8- with (1.5 Nm) ⇒ Heating, air
conditioning; Rep. gr. 80 ; Heating .

1.4 Cross support/Instruments panel - re‐

moval and installation

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

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1.4.1 Removal
– Turn ignition off.
– Disconnect battery earth strap⇒ Electrical system; Rep. gr.
27 ; Starter, alternator, battery .
– Remove the instrument panel ⇒ page 74 .
– Remove the center console ⇒ page 8 .
– Remove passenger side airbag ⇒ page 65 .
– Remove fastening screws -arrows- that fasten the steering
column on the cross support.

– Remove the fastening screw -1-.

– Remove the air baffle channel of the windscreen -4-.
– Remove fastening screws -2- (2 units).
– Remove the central air-streamer channel -3-.

– Remove the fastening screw -2-.

– Remove the air duct -1-.

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– Remove fastening screws -1- (2 units) on air conditioning sup‐

port.

– Remove the fastening screws -1- from cross support.

– Press the relay holder -2- backwards.

– Unplug the harness from the instruments panel, in the areas

-1- and -2-.
– Remove the Central control unit for the convenience system -
J393- ⇒ General body repairs, exterior; Rep. gr. 57 ; Front
doors/components/central lock .
– Disengage the support from the Central control unit for the
convenience system -J393- .

– Remove fastening screws -1- and -4-, with nut -3- on the in‐
strument panel support -2-.

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– Remove fastening screws -arrows- (2 units) on the left and

right sides of the instrument panel support.

– Remove fastening screws -1- (3 units).

– Remove the transversal support -2- from the instrument panel.

Note

To unplug and remove the cross support -2-, it is recommended the help of a second operator.

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1.4.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

To install and remove the cross support -2-, it is recommended

the help of a second operator.

– Install the transversal support -2- for the instrument panel.

– Tighten fastening screws -1- to (20 Nm) torque.

– Tighten fastening screws -arrows- to (12 Nm) on the left and

right sides of the instrument panel support.

– Fasten the fastening screws in the following sequence: -1- and

-4- on instrument panel support-2- to (12 Nm).
– Install nut -3- on the instrument panel support -2-.
– Insert the support on the Central control unit for the conven‐
ience system -J393- .

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– Install the Central control unit for the convenience system -

J393- ⇒ General body repairs, exterior; Rep. gr. 57 ; Front
doors/components/central lock .
– Insert the instrument panel harness in areas -1- and -2-.

– Press the relay holder -2- forwards.

– Tighten fastening screws -1- to (4 Nm) behind the cross sup‐
port.

– Tighten fastening screws -1- to (12 Nm) on air conditioning

support.

– Install air duct -1-.

– Screw on the fastening screw -2- with torque of (1.5 Nm).
– Install air baffle channel on the windscreen -4-.

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– Screw on the fastening screw -1- with torque of (3.5 Nm).

– Install the central air-streamer channel -3-.
– Tighten fastening screws -2- to (3.5 Nm) torque.

– Tighten screws -arrows- that fasten the steering column to the

cross support to torque (25 Nm).
– Install passenger side airbag ⇒ page 65 .
– Install the center console ⇒ page 8 .
– Install the instruments panel ⇒ page 74 .
– Turn on the ignition.

Caution

Please take care and make sure that no-one stays inside the
vehicle.

– Connect the battery's mass cable ⇒ Electrical equipment ;

Rep. gr. 27 ; Start-up engine, alternator, battery .

1.5 Instrument panel cover - remove and in‐

stall

1.5.1 Removal
– Remove the left air baffle from the instrument panel.
– Remove the center console ⇒ page 8 .
– Remove the central frame on instrument panel:
Vehicles with glove compartment ⇒ page 15 .

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Vehicles without glove compartment ⇒ page 13 .

– Remove fastening screws -1- (4 units) and disengage the in‐
strument panel cover -3- with Wedge -T10039/1- .

1.5.2 Installation
The installation occurs in the reversal sequence of removal.
– Tighten fastening screws -1- to (1.5 Nm) torque.

1.6 Steering column covering - remove and

install

1.6.1 Removal

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

– Remove the Ignition device for the driver's airbag -N95- .

Vehicles with (3 spokes steering wheel): ⇒ page 59 .
Vehicles with (4 spokes steering wheel): ⇒ page 61 .
– Remove steering wheel (3-spoke steering wheel) ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering .
– Remove steering wheel (4-spoke steering wheel) ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering .

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– Disengage the upper covering -1- from the steering column

upwards.
– Remove fastening screws -2- and -3-.
– Carefully pull backwards the lower lining -4- of the steering
column.

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1.6.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -2- to (1.5 Nm) torque.
– Tighten fastening screws -3- to (3.5 Nm) torque.

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

– Connect the battery's mass cable ⇒ Electrical equipment ;

Rep. gr. 27 ; Start-up engine, alternator, battery .

1.7 Steering column covering with adjust‐

ment - remove and install
Special tools and workshop equipment required
♦ Spatula -VW 037-

♦ Wedge -3409-

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♦ Hook -T 10118- .

WARNING

Before making any work in the electric system, it is necessary

to disconnect the battery's mass cable. ⇒ Electrical system;
Rep. gr. 27 ; Starter, alternator, battery .

Note

♦ Check if the vehicle has a coded radio, if so, request the anti-
theft code before disconnecting the mass cable from the bat‐
tery.
♦ When reconnecting the battery, check if the vehicle's equip‐
ment (radio, clock, electric locks, electric windows, etc.), ac‐
cording to the repair guide and/or instructions of use.

1.7.1 Removal
– Turn ignition off.
– Disconnect the battery's mass cable ⇒ Electrical equipment ;
Rep. gr. 27 ; Start-up engine, alternator, battery .
– Remove the Ignition device for the driver's airbag -N95- .
Vehicles with (3 spokes steering wheel): ⇒ page 59 .
Vehicles with (4 spokes steering wheel): ⇒ page 61 .

Caution

Observe the safety measures to work with the Airbag .

– Remove steering wheel (3-spoke steering wheel) ⇒ Running

gear, axles, steering; Rep. gr. 48 ; Steering .
– Remove steering wheel (4-spoke steering wheel) ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering .
– Remove the instrument panel cover. ⇒ page 86

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– Remove the Combined instrument -K- ⇒ Electrical system;

Rep. gr. 90 ; Instrument case, indicators .
– Disengage upper covering on steering column -3- according
to the movement -arrow- of the instrument panel -2- using a
Spatula -VW 037- or a Wedge -3409- .
– Remove the steering column upper covering -3-.

WARNING

♦ Remove carefully the upper covering on the steering col‐

umn -3-, through the opening on cross support -1-, since
it may be damaged.

Caution

When removing upper covering on steering column -3-, there

is risk of hand injuries.

– Remove fastening screws -1- and -2-.

– Pull carefully the lower covering on steering column back‐
wards -3-.

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1.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install upper covering on steering column -1- according to the
movement -arrow- using a Spatula -VW 037- or a Wedge
-3409- .

Caution

When installing upper covering on steering column -1-, there

is risk of hand injuries.

– Pull fabric of the upper covering on steering column -1- ac‐

cording to motion -arrow-, through opening on cross support
-2-, by using the Hook -T 10118- .

WARNING

♦ Pull carefully the fabric of the upper covering on steering

column -1-, since it may be damaged.

– Tighten fastening screws -1- to (1.5 Nm) torque.

– Screw on the fastening screw -2- with torque of (3.5 Nm).

WARNING

When connecting the battery's mass cable, make sure that no

one is inside the vehicle.

– Connect the battery's mass cable ⇒ Electrical equipment ;

Rep. gr. 27 ; Start-up engine, alternator, battery .

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2 Doors' linings (2 doors)

2.1 Tools
Special tools and workshop equipment required
♦ Wedge -T10039/1-

2.2 Driver's side front door lining - remove

and install

2.2.1 Removal

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– Turn ignition off.

Vehicles with electrical glass activation mechanism:
– Disengage the frame from switches -7- with Wedge -
T10039/1- and disengage the connector.
Vehicles with manual glass activation mechanism:
– Remove the window crank ⇒ General body repairs, exterior;
Rep. gr. 64 ; Windscreen, windows, window mechanisms .
For all vehicles:
– Remove fastening screws -8- (7 units).
– Remove door lining -9- by using Wedge -T10039/1- .
– Unplug the activation cable -4- of the door's internal pull -6-.
– If existing, disconnect the connectors from the LED (anti-theft
alarm system) and the external electric rear-view mirror.
– Disengage the reinforcement -3- (only Europe models).

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2.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Before assembling, check the fastening clips -1- for damages

and, if necessary, replace them.
♦ Check the state of rivet nuts -2-. In order to install it, use the
POP NUT rivet nut applier -VAG 1765B- or POP NUT rivet nut
applier -EQ 7422- .

For all vehicles:

– Tighten fastening screws -8- to (2 Nm) torque.

2.3 Front passenger's side door lining - re‐

move and install

2.3.1 Removal

2. Doors' linings (2 doors) 95

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– Turn ignition off.

Vehicles with electrical glass activation mechanism:
– Disengage the frame from switches -4- with Wedge -
T10039/1- and disengage the connector.
Vehicles with manual glass activation mechanism:
– Remove the window crank ⇒ General body repairs, exterior;
Rep. gr. 64 ; Windscreen, windows, window mechanisms .
For all vehicles:
– Remove fastening screws -3- (7 units).
– Remove lining -2- with the Wedge -T10039/1- at the fastening
points.
– Disengage the activation cable -7- of the internal door handle
-5-.
– If applicable, disengage connector on the electric external
rear-view.
– Disengage the reinforcement -8- (only Europe models)

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2.3.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Before assembling, check the fastening clips -1- for damages

and, if necessary, replace them.
♦ Check the state of rivet nuts -9-. In order to install it, use the
POP NUT rivet nut applier -VAG 1765B- or POP NUT rivet nut
applier -EQ 7422- .

For all vehicles:

– Tighten fastening screws -3- to (2 Nm) torque.

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3 Doors' linings (4 doors)

3.1 Tools
Special tools and workshop equipment required
♦ Wedge -T10039/1-

3.2 Front door lining - assembly overview

1 - Rivet nuts
❑ In order to install it, use
the POP NUT rivet nut
applier -VAG 1765B- or
POP NUT rivet nut ap‐
plier -EQ 7422- .
2 - Hook of the lock activation
cable
3 - Lock activation cable
❑ Removal and installa‐
tion ⇒ Body - External
assembly work; Rep.
gr. 57 ; Front doors/
components/central
locking
4 - Cable support
❑ On lining
5 - Internal pull
❑ Removal and installa‐
tion ⇒ Body - External
assembly work; Rep.
gr. 57 ; Front doors/
components/central
locking
6 - Switch frame
7 - Screw
❑ 2 Nm
8 - Door lining
❑ Remove and install
⇒ page 99
9 - Clip
❑ Replace, as required

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3.3 Front door lining - remove and install

3.3.1 Removal
Vehicles with power window drive mechanism:
– Disengage the frame from switches -6- with Wedge -
T10039/1- and disengage the connectors.

Vehicles with manual glass activation mechanism:

– Remove the window crank ⇒ General body repairs, exterior;
Rep. gr. 64 ; Windscreen, windows, window mechanisms .
For all vehicles:

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– Remove fastening screws -7-.

– Disengage the lining -8- with Wedge -T10039/1- at the fas‐
tening points.
– Disengage the internal handle operating cable -3- from the
support -4-. Then, disengage the hook -2- from the internal
handle -5-.
– Disengage the LED connectors (Anti-theft alarm system) and
the external electric rear-view mirror, as applicable.

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3.3.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Before assembling, check the fastening clips -9- for damages

and, if necessary, replace them.
♦ Check the state of rivet nuts -1-. In order to install it, use the
POP NUT rivet nut applier -VAG 1765B- or POP NUT rivet nut
applier -EQ 7422- .

For all vehicles:

– Tighten fastening screws -7- to (2 Nm) torque.

3.4 Rear door lining - general overview of assembly

1 - Clip
❑ Replace, as required
2 - Rivet nuts
❑ In order to install it, use
the POP NUT rivet nut
applier -VAG 1765B- or
POP NUT rivet nut ap‐
plier -EQ 7422- .
3 - Hook of the lock activation
cable
4 - Lock activation cable
❑ Removal and installa‐
tion ⇒ Body - External
assembly work; Rep.
gr. 58 ; Front doors/
components/central
locking
5 - Cable support
❑ On lining
6 - Internal pull
❑ Removal and installa‐
tion ⇒ Body - External
assembly work; Rep.
gr. 58 ; Front doors/
components/central
locking
7 - Screw
❑ 2 Nm
8 - Door lining
❑ Remove and install
⇒ page 102

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3.5 Rear door lining - remove and install

3.5.1 Removal
Vehicles with manual glass activation mechanism:
– Remove the window crank ⇒ General body repairs, exterior;
Rep. gr. 64 ; Windscreen, windows, window mechanisms .
For all vehicles:

– Remove fastening screws -7- from lining.

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– Disengage the lining -8- with Wedge -T10039/1- at the fas‐

tening points.
– Disengage the internal handle operating cable -4- from the
support -5-. Then, disengage the hook -3- from the internal
handle -6-.
– Disengage the connectors from the power window mecha‐
nism, as applicable.

3.5.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Before assembling, check the fastening clips -1- for damages

and, if necessary, replace them.
♦ Check the state of rivet nuts -2-. In order to install it, use the
POP NUT rivet nut applier -VAG 1765B- or POP NUT rivet nut
applier -EQ 7422- .

For all vehicles:

– Tighten fastening screws -7- to (2 Nm) torque.

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4 Lining of columns and sides

4.1 Tools
Special tools and workshop equipment required
♦ Lever -T10039-
♦ Wedge -T10039/1-

♦ Spade -VW 037- .

♦ Wedge -3409-

4.2 Column A lining - remove and install

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.2.1 Removal
– Remove the roof`s safety handle ⇒ page 20 .

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– Turn ignition off.

– Disengage A pillar covering -1-, starting from the centre and
going forward and backward.
– In the front area, unplug the instruments panel.
– At the rear section, pull from the pillar B lining.
– Disconnect the connector -3- from the tweeter and remove the
lining of column A -1-.

4.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

♦ Any and all repair involving the lining removal, should necessarily have the fastening clamps -2-, replaced
by new parts.
♦ After installing, check if the lining -1- is completely fitted to the door's edging.

4.3 Column B lining (2 doors) - removal and

installation

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.3.1 Removal
– Remove the fastening of the front seatbelt in column B.

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– Remove the roof`s safety handle ⇒ page 20 .

– Partially unplug the upper lining of column A -1-.
– Disengage the rear side lining -4-in the region close to B-pillar
lining.
– Remove the fastening screw -5-.
– Disengage the lining from column B -3- in the upper area and
pull it ahead and out of the lining of column C -2-.

4.3.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Check and replace the lining fastening clips, if necessary.

♦ Check if the door's inner edging lip and the side glass inner
edging finish the lining's edges.

– Screw on the fastening screw -5- with torque of (1.5 Nm).

4.4 Column B linings (4 doors) - assembly overview

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1 - Clip
2 - Column B upper lining
❑ Remove and install
⇒ page 108
3 - Screw
4 - Lower lining of column B
❑ Remove and install
⇒ page 110

4.5 Column B lining (4 doors) - removal and

installation

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.5.1 Removal
– Remove the lower lining of column B -4- ⇒ page 110 .
– Remove the lining of column A ⇒ page 104 .
– Remove the upper fastening of the safety belt.

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– Remove the fastening screw -3- from the belt's upper fastening
point -2-.
– Remove the upper lining of column B -2-.

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4.5.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Check and replace the lining fastening clips -1-, if necessary.

♦ Check that the finishing tab of the front and rear doors reach
the edges of the lining.

– Tighten fastening screw -3- to torque (1,5 Nm) on upper B-

pillar lining -2-.

4.6 Column B lining (4 doors) - removal and

installation

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.6.1 Removal
– Remove the rear door sill's trim ⇒ page 23 .
– Remove the rear door sill's trim ⇒ page 26 .
– Remove the lower lining by disengaging its tab -1- from the
upper pillar B lining.

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4.6.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

All and any repairs involving removal of lining must mandatorily

include replacing the fastening clips by new parts.

4.7 Column C lining (2 doors) - removal and

installation

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.7.1 Removal
– Remove the luggage compartment cover.
– Fold the rear seat rest.
– Unplug the side lining ⇒ page 115 .
– Remove seat belt fastening point, rear area ⇒ page 49 .

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– Remove fastening screws -2- (2 units).

– Disengage the lining from column C -1- with the aid of a Spat‐
ula -VW 037- , Wedge -T10039/1- or Wedge -3409- ..
– At the front area, pull the B pillar lining out.
– Pass the safety belt through the column C lining -1- and re‐
move the lining.

4.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

♦ Any and all repair involving the lining removal, should necessarily have the fastening clamps -3-, replaced
by new parts.
♦ After installing, check if the lining -1- is completely fitted to the seating of the rear lid sealing.

– Tighten fastening screws -2- to (1.5 Nm) torque.

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4.8 Pillar C lining (4 doors) - assembly overview

1 - Finishing of column C
❑ Remove and install
⇒ page 114
2 - Screw
❑ 2 units
❑ 1.5 Nm
3 - Clips

4.9 Column C lining (4 doors) - removal and

installation

4.9.1 Removal
– Remove the luggage compartment cover.
– Remove the rear door sill trim ⇒ page 26 .
– Remove the lower fastening point of the rear safety belt
⇒ page 49 .
– Fold the rear seat rest.
– Remove the screws and safety handle, as applicable
⇒ page 20 .

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– Remove fastening screws -arrows- (2 units) from C pillar lin‐

ing.
– Remove the pillar C lining, disengaging it from the pillar B.

4.9.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

All and any repairs involving removal of lining must mandatorily

include replacing the fastening clips by new parts.

– Tighten fastening screws -arrows- to (1,5 Nm) on upper C-

pillar lining.

4.10 Side lining (2 doors) - removal and in‐

stallation

Note

The removal and installation is described for the right side of the
vehicle. The removal and installation for the left side of the vehicle
is made in an analogue manner.

4.10.1 Removal
– Remove the door sill's trim ⇒ page 21 .
– Remove the back seat ⇒ page 167 .

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– Remove side lining -1- starting at the front side, with Wedge -
T10039/1- .
– At the rear section, pull the fastening hooks -2- out from the
pillar C lining, and remove the side lining -1-.

4.10.2 Installation
– The installation occurs in the reversal sequence of removal,
observing the following instructions:

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Note

♦ Any and all repair involving the lining removal, should necessarily have the fastening clamps -3-, replaced
by new parts.
♦ After installation, check if the lining -1- is fully at the door and window sealing fittings.

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5 Linings of the luggage compartment

5.1 Tools
Special tools and workshop equipment required
♦ Lever -T10039-
♦ Wedge -T10039/1-

5.2 Rear lid lining - remove and install

5.2.1 Removal

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– Remove the fastening screw -3-.

– Remove the lining -1- with the help of a Wedge -T10039/1-
through the fastening points and remove them from the rear
lid.

5.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

Before assembling, it is necessary to check the fastening clamps -2-for damages and, if necessary, replace
them.

– Screw on the fastening screw -3- with torque of (1.5 Nm).

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5.3 Luggage compartment cover - removal and installation

1 - Joint pin
❑ Remove the fastening
pin-2- pushing it, and
them unplug the pin
from the lid.
2 - Fastening pin
3 - Articulation housing
4 - Cable
5 - Trunk cover
❑ Unplug the cables of the
articulation pins and un‐
plug the the articulation
housing cover.
6 - Cover articulation

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5.4 Lower lining and cover of the rear panel - removal and installation

1 - Rear panel covering

❑ Remove the screws -2-.
2 - Screw
❑ 1.5 Nm
3 - Bushing
4 - Rear panel lower cover.
❑ Disengage the pressure
buttons and remove the
cover.

5.5 Luggage compartment side lining - re‐

move and install
Special tools and workshop equipment required
♦ Ejector lever -80-200-

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1 - Pressure button
❑ Replace, as required
2 - Lateral lining of the trunk
❑ The part has a couple of
adhesive foam strips for
fastening to the rear
wheel case.
❑ Removal
– Fold the rear seat rest.

– Remove the tail light

fastening screw ⇒ Elec‐
trical system; Rep. gr.
94 ; Switches, lights and
external lamps

– Remove luggage net

⇒ page 16 .

– Remove the pressure

buttons -1- using the
Ejector lever -80-200- .

– Detach the covering

from the rear wheel
case.

Note

For the 4-door models, remove the

lower pillar C lining.
❑ Installation
The installation occurs in the
reversal sequence of removal.

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6 Bonnet noise insulation

6.1 Bonnet noise insulation - remove and

install
Special tools and workshop equipment required
♦ Wedge -T10039/1-

♦ Spade -VW 037- .

♦ Wedge -3409-

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1 - Bonnet noise insulation

❑ Remove the clamps -2-
using a Wedge -
T10039/1- or Spatula -
VW 037- or Wedge
-3409- and remove
noise insulation.
2 - Clip
❑ Replace it if necessary.
3 - Bonnet

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7 Roof linings (2 ports)

7.1 Pre-molded overhead lining - removal

and installation

7.1.1 Removal
– Remove the roof`s safety handle ⇒ page 20 .
– Remove lining from column A ⇒ page 104 .
– Unplug the doors' sills ⇒ page 21 .
– Fold the rear seat rest.
– Unplug the side linings ⇒ page 115 .
– Remove the seat belt guide, on the front section.
– Remove the B pillar linings ⇒ page 106 .
– Remove the C pillar linings ⇒ page 111 .
– Remove the parasols ⇒ page 18 .
– Remove vanity mirror lights ⇒ Electrical system ; Rep. gr. 96 ;
Switches, lights and internal lamps, alarm .
– Remove internal light ⇒ Electrical system ; Rep. gr. 96 ;
Switches, lights and internal lamps, alarm .

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– Pull the roof's pre-molded lining -1- in the rear area, out of the
rear lid sealing -2-.
– Lower the pre-molded roof lining -1- evenly and remove to the
rear section of the vehicle (luggage compartment).

7.1.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

♦ Before the assembly, check the spacers -3- for the right seating and, if necessary, fasten with proper glue.
♦ After installing, check if the roof's pre-molded lining -1- is completely fitted to the seating of the rear lid
sealing-2-.

7.2 Pre-molded roof lining (sunroof) - re‐

moval and installation

7.2.1 Removal
– Remove the roof`s safety handle ⇒ page 20 .
– Remove lining from column A ⇒ page 104 .

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– Remove the cover -5- of the Sliding sunroof's activating motor

-V1- and disconnect the connector of the ultra-sound sensor
for alarm system -G209- .
– Remove Sliding sunroof motion control unit -J245- ⇒ General
body repairs, exterior; Rep. gr. 60 ; Sunroof .
– Remove fastening screws -6-.
– Unplug the doors' sills ⇒ page 21 .
– Fold the rear seat rest.
– Unplug the side linings ⇒ page 115 .
– Remove the seat belt guide, on the front section.
– Remove the B pillar linings ⇒ page 106 .
– Remove the C pillar linings ⇒ page 111 .
– Remove the parasols ⇒ page 18 .
– Remove vanity mirror lights ⇒ Electrical system ; Rep. gr. 96 ;
Switches, lights and internal lamps, alarm .

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– Pull the roof's pre-molded lining -7- in the rear area, out of the
rear lid sealing -1-.
– Lower the pre-molded roof lining -7- evenly and remove to the
rear section of the vehicle (luggage compartment).

7.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

♦ Before the assembly, check the spacers -2- for the right seat‐
ing and, if necessary, fasten with proper glue.
♦ After installing, check if the lining of the pre-molded roof -7- is
completely fitted to the seating of the hatch finishing -3'-.

– Screw on the fastening screw -6- with torque of (1.5 Nm).

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8 Roof lining (4 ports)

8.1 Pre-molded overhead lining - general overview of assembly

1 - Internal lighting lamp

❑ Remove and install ⇒
Electrical system; Rep.
gr. 96 ; Switches, lights
and external lamps,
alarm
2 - Screws
❑ 2 units
❑ 2 Nm
3 - Fastening support
❑ Remove and install
⇒ page 18 .
4 - Fastening support
❑ Remove and install
⇒ page 18 .
5 - sun visor
❑ Remove and install
⇒ page 18 .
6 - Spacer
7 - Roof lining
❑ remove and install
⇒ page 132
8 - Rear door packing
9 - Door packing

8.2 Pre-molded overhead lining - removal

and installation

8.2.1 Removal
– Remove the roof`s safety handle ⇒ page 20 .
– Remove lining from column A ⇒ page 104 .
– Remove the upper linings of column B ⇒ page 108 .

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– Remove the C pillar linings ⇒ page 114 .

– Remove the sun visors -5- ⇒ page 18 .
– Remove vanity mirror lights ⇒ Electrical system ; Rep. gr. 96 ;
Switches, lights and internal lamps, alarm .
– Remove internal lighting lamp -1- ⇒ Electrical equipment;
Rep. gr. 96 ; Switches, lights and internal lamps, alarm .
– Disengage the rear end of the roof lining -7-, removing it from
the rear lid packing -8-..
– Remove pre-molded roof lining 2 with care.

8.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Before the assembly, check the spacers -6- for the right seat‐
ing and, if necessary, fasten with proper glue.
♦ After installing, check if the roof's pre-molded lining -7- is com‐
pletely fitted to the seating of the rear lid sealing-8-.

– Screw on the fastening screw -2- with torque of (2 Nm).

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9 Noise insulation

9.1 Tools
Special tools and workshop equipment required
♦ Thermal blower -V.A.G 1416-

9.2 Assembly overview

1 - Door
2 - Internal panel of the rear lid
3 - External panel of the rear lid
4 - Noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
5 - Noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
6 - Noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-

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1 - Noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
2 - Floor of the luggage com‐
partment
3 - Noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
4 - Rear outer side panel

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1 - Engine compartment's par‐

tition panel
2 - Noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
3 - Noise insulation
❑ 2 units (one in each end)
❑ Self-adherent
4 - Direct noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
5 - Left noise insulation
❑ Magnetized and thermal
flux
❑ Install using the Hot air
blower -VAG 1416-
6 - Noise insulation
❑ Self-adherent

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1 - Fastening clip
2 - Partition panel's upper
acoustic insulation
3 - Fastening nut
4 - Fastening clip
5 - Partition panel's acoustic in‐
sulation
6 - Fastening clip
7 - Partition panel

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1 - Transversal support
2 - Noise insulation

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1 - Roof
2 - Roof's rear acoustic insula‐
tor
❑ Self-adherent
3 - Roof's front acoustic insu‐
lator
❑ Self-adherent

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1 - Roof
❑ For vehicles with sun‐
roof (Europe only)
2 - Roof's rear acoustic insula‐
tor
❑ Self-adherent

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1 - Floor lining
❑ Remove and install
⇒ page 144
2 - Front floor's acoustic insu‐
lation
3 - Rear floor's acoustic insu‐
lation
4 - Rear acoustic insulator

9. Noise insulation 141

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1 - Tunnel's acoustic insulator

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1 - Front lid acoustic insulator

❑ For different versions.
2 - Noise insulation
❑ For different versions.

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1 - Noise insulation
2 - Acoustic insulator

9.3 Floor lining - remove and install

9.3.1 Removal
– Remove front seats ⇒ page 146 .
– Remove the back seat ⇒ page 167 .
– Remove the side linings ⇒ page 115 .
– Remove the door sill's trim ⇒ page 21 .
– Remove the console ⇒ page 8 .
– Remove the fastening of the front safety belt from the floor.
– Remove drive cable lever in bonnet latch ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Covers
– Remove the accelerator pedal limiter.

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– Pull floor lining according to motion -arrows-.

– Remove the lining, disengaging it.

9.3.2 Installation
The installation occurs in the reversal sequence of removal.

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72 – Seat Structure
1 Front seats

1.1 Left front seat - remove and install

Special tools and workshop equipment required
♦ Airbag adapter -VAS 5232/1-

Note

♦ During the removal and installation works, it is necessary to

consider some differences, depending on the version of the
respective equipment.
♦ After connecting the battery, make sure that the vehicle equip‐
ment (radio, clock, power window mechanisms) is checked
according to the description on the repair and/or instruction
manuals.

1.1.1 Removal

Note

♦ Before disconnecting the ignition cable and earth strap, the

mechanic must perform an electrostatic discharge (by briefly
touching any grounded metallic part on the door lock or the
vehicle body).
♦ The seat is removed along with the rails.

– Disconnect battery earth strap⇒ Electrical system; Rep. gr.

27 ; Starter, alternator, battery .

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– Push the seat ahead.

– Remove fastening screws -2- and -3-.
– Push the seat back.
– Remove fastening screws -1- and -4-.

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– Disconnect the seat belt latch connector -2- from the connec‐
tor support -4-
– Disengage side airbag connector -1- from the connector sup‐
port -4-.
– If existing, disengage seat heating connector -3- from the con‐
nector support-4-
– Connect Airbag adapter -VAS 5232/1- in side airbag connec‐
tor -1-.

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1.1.2 Installation

Note

♦ The fastening pins -5- determinate the seat framework position.

♦ Before the installation, clean threads on screws -1,2, 3 and 4-, and apply new chemical threadlocker.

– Push the seat ahead.

– Screw on the fastening screw -2- with torque of (24 Nm).
– Push the seat back.
– Screw on the fastening screws -1- and -4-, in this sequence,
both with torque of (24 Nm).
– Push the seat ahead.
– Screw on the fastening screw -3- with torque of (24 Nm).

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Note

If the Airbag control lamp (K75) indicates a failure after the as‐
sembly, it is necessary to erase and check the fault memory again
with the Diagnosis, Measurement and Information system -VAS
5051A/52- => Adapt the components

1.2 Right front seat - remove and install

Special tools and workshop equipment required
♦ Airbag adapter -VAS 5232/1-

Note

♦ During the removal and installation works, it is necessary to

consider some differences, depending on the version of the
respective equipment.
♦ After connecting the battery, make sure that the vehicle equip‐
ment (radio, clock, power window drive) is checked according
to the description on the repair and/or instruction manuals.

1.2.1 Removal
– Disconnect battery earth strap⇒ Electrical system; Rep. gr.
27 ; Starter, alternator, battery .

Note

♦ Before disconnecting the ignition cable and earth strap, the

mechanic must perform an electrostatic discharge (by briefly
touching any grounded metallic part on the door lock or the
vehicle body).
♦ The seat is removed along with the rails.

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– Push the seat ahead.

– Remove fastening screws -2- and -3-.
– Push the seat back.
– Remove fastening screws -1- and -4-.

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– Disengage side airbag connector -1- from the connector sup‐

port -3-.
– If existing, disconnect the seat heating connector -2- from the
connector support
– Connect Airbag adapter -VAS 5232/1- in side airbag connec‐
tor -1-.

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1.2.2 Installation

Note

♦ The fastening pins -5- determinate the seat framework position.

♦ Before the installation, clean threads on screws -1,2, 3 and 4-, and apply new chemical threadlocker.

– Push the seat ahead.

– Screw on the fastening screw -2- with torque of (24 Nm).
– Push the seat back.
– Screw on the fastening screws -1- and -4-, in this sequence,
both with torque of (24 Nm).
– Push the seat ahead.
– Screw on the fastening screw -3- with torque of (24 Nm).

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Note

If the Airbag control lamp (K75) indicates a failure after the as‐
sembly, it is necessary to erase and check the fault memory again
with the Diagnosis, Measurement and Information system -VAS
5051A/52- => Adapt the components

1.3 Front seat cover - assembly overview

1 - Backing adjustment mech‐

anism handle
2 - Cover of the front seat back‐
ing adjustment mechanism
(tunnel side)
3 - Cover of the front seat back‐
ing adjustment mechanism
(tunnel side)
4 - Height adjustment lever
5 - Screw
❑ 2 units
❑ 5.5 Nm
6 - Cover cap
7 - Front seat side cover
❑ For the driver's seat, in‐
stalled in the left side.
❑ For the passenger's
seat, installed in the
right side.
8 - Screw
❑ 3 units
❑ 2.5 Nm

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1.4 Front seat cover (with parallel height

regulation) - removal and installation

1.4.1 Removal

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

– Remove the front seat ⇒ page 146 .

– Unplug the backing adjustment mechanism handle -1- pulling

it outwards.
– Unslot the covers -2- and -3-.
– Remove the cover caps -6-, together with the fastening screws
-5- and remove the height adjustment lever-4-.

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– Remove the fastening screws -8- (3 units) and remove the

cover -7-.

1.4.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install the cover -7-, screw on the fastening screws -8- with
torque of (2.5 Nm).
– Install the height adjustment lever -4-, together with the fas‐
tening screws -5- with torque of (5.5 Nm) and its respective
cover caps -6-.
– Install the covers -2- and -3-.
– Install the front seat ⇒ page 146 .

1.5 Fire extinguisher support - removal and

installation

Note

The support is assembled in the front right seat (passenger's seat)

1.5.1 Removal
– Remove the fire extinguisher .
– Remove fastening screws -3-.
– Remove the washers -2- and the support -1- of the seat frame‐
work.

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1.5.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -3- to (3 Nm) torque.

1.6 Front seat head rest - assembly overview

1 - Front seat head rest

❑ Remove and install
⇒ page 157 .
2 - Head rest guide
❑ Remove and install
⇒ page 165 .
3 - Front seat backing
❑ Remove and install
⇒ page 158 .

1.6.1 Front seat head rest - removal and in‐

stallation
Removal:

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

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– Press the lock -arrow- according to detail, and remove the

head rest -1- pulling it upwards.
Installation:
– The installation occurs in the reversal sequence of removal.

1.6.2 Front seat headrest (Europe only) - re‐

moval and installation
Removal:

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

– Press the lock -2- according to detail -arrow-, and remove the
head rest -1- pulling it upwards.
Installation:
– The installation occurs in the reversal sequence of removal.

1.7 Front seat backing - removal and instal‐

lation

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

1.7.1 Removal
– Remove the front seat ⇒ page 146 .
– Remove the front seat lining (with parallel height adjustment)
⇒ page 155 .

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– Unplug the right and left locks -2- of the check pins with a
screwdriver.
– Unlock the backing -1- and fold it forward.
– Unplug the backing -1- of check pins with a screwdriver and
remove the seat assembly -4-.

1.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

♦ Before assembling, it is necessary to check the locks -2- for damages and, if necessary, replace them.
♦ Before the assembly, the right and left bushings -3- (2 units) should be placed in the backing's respective
housings -1-.

1.8 Front seat backrest (Europe only) - re‐

move and install

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

1.8.1 Removal
– Remove the front seat ⇒ page 146 .

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– Remove the front seat lining (with parallel height adjustment)

⇒ page 155 .
– Remove fastening screws -2-.
– Unlock the backing -1- and fold it forward.
– Unplug the backing -1- of check pins with a screwdriver and
remove the seat assembly -3-.

1.8.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -2- to (24 Nm) torque.

1.9 Parallel height adjustment - removal and

installation

1.9.1 Removal
– Remove the front seat ⇒ page 146 .
– Remove the front seat lining ⇒ page 155 .

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– Remove the fastening screws -arrows-.

– Unplug the parallel height adjustment -1- with a screwdriver.

1.9.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -3- to (10 Nm) torque.

1.10 Cable for unlocking the backing - assembly overview

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1 - Fastening lever
2 - Left cable
❑ Remove and install
⇒ page 163
3 - Right cable
❑ Remove and install
⇒ page 163
4 - Cable guide
5 - Left drawspring
6 - Right drawspring

1.11 Cable for unlocking the backing - remov‐

al and installation

Note

The removal and installation is described for the front left seat.
The removal and installation for the front right seat is made in an
analogue manner.

1.11.1 Removal
– Remove the front seat ⇒ page 146 .
– Remove the front seat lining ⇒ page 155 .
– Remove the front backing ⇒ page 158 .
– Remove the front seat's lining and stuffing ⇒ page 193 .

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– Unplug the left drawspring -5-.

– Unplug the right drawspring -6-.
– Unplug the cables -2- and -3-in the lower part of the backing
and remove them from the backing framework.
– Remove the guide of cables -4- with a 90° turning clockwise.
– Unplug the cables -2- and -3- of the fastening lever -1- and pull
them out of the backing framework.

1.11.2 Installation
The installation occurs in the reversal sequence of removal.

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1.12 Front seat head rest guide - removal and

installation

1.12.1 Removal

Note

♦ The removal and installation is described for the front left seat.
The removal and installation for the front right seat is made in
an analogue manner.
♦ There are two different guides of head rests, one with the un‐
locking button -1- or -2- and the other without the button -3-.
♦ There are two types of guides with unlocking button: Turned
to the front of the vehicle -2- and, for the European market,
turned to the left door -1-

Head rest guide (bushing) with unlocking button -1- or -2-

– In the opposite side to the unlocking button, press the stuffing
down and unlock the lock -arrow A- with a screwdriver.

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Head rest guide (bushing) without unlocking button -3-

– In the front of the guide without unlocking button, press the
stuffing down and unlock the lock -arrow A- with a screwdriver.
– Remove the head rest guides pulling them upwards.

1.12.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ Before assembling, it is necessary to check the head rests

guides (bushings) for damages and, if necessary, replace
them.
♦ For the European market, in the head rest shafts, in the guide
locking area, a thin layer of Vaseline should be applied.

1.13 Object holder under the driver's seat - removal and installation

1 - Sliding rail
❑ Welded to the seat's
framework
2 - Locks
3 - Objects holder
Removal

– Remove the front seat

⇒ page 146 .

– Pull the object holder

completely ahead
-arrow A-.

– Press the locks -2- and

pull the object holder up‐
wards -arrow B-.

Installation

– Place the object holder

in the sliding rail and pull
it below the seat.

Note

Lubricate the object holder and the

sliding rail with Lubricant spray -G
052 778 A2-

– Install the front seat

⇒ page 146 .

4 - Objects holder lining

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2 Rear seats

2.1 Back seat - remove and install

2.1.1 Removal

Note

The picture represents the seat with longitudinal adjustment. The

removal of seat without longitudinal adjustment is made in an an‐
alogue manner.

– Remove the fastening nuts -3- (4 units) and fold the hinges
-2- (2 units) upwards.

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Caution

For models exported to Europe, there is a spring in each hinge

-2- that reduces the effort in folding the seat and backrest to‐
gether. Be careful when removing the nuts -3-.

– Fold the seat assembly -1- forwards and, with help from a
second operator, raise and remove it through the back of the
vehicle.

2.1.2 Installation

Note

To install the seat in vehicles exported to Europe, position seat in

the folded condition due to the spring pressure on the seat hinge.

– Position the seat assembly in the folded condition and install

the nuts -1-.

Note

The installation of nuts -1- should be made with the seat assembly
folded due to the pressure that the spring exerts under the hinge.

– Return the seat assembly to the use position and fasten the
nuts -1- with torque of (24 Nm).

2.2 Rear seat (one-piece, without longitudinal adjustment) - assembly overview

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1 - Rear seat backing (one-

piece, without longitudinal ad‐
justment)
❑ Remove and install
⇒ page 169 .
2 - Drawing handle
3 - Double locking
❑ Remove and install
⇒ page 50 .
4 - Rear seat lock assembly
without longitudinal adjust‐
ment (left side)
5 - Screw
❑ 1 unit.
❑ 40 Nm
6 - Seat framework
7 - Screw
❑ 1 unit.
❑ 40 Nm
8 - Rear seat lock assembly
without longitudinal adjust‐
ment (right side)
9 - Abdominal safety belt with
simple fastening
❑ Remove and install
⇒ page 50 .

2.3 Backing (one-piece, without longitudinal

adjustment) - removal and installation

2.3.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's backing lining and stuffing ⇒ page 205 .

Note

♦ The lining do not need to be separated from the stuffing.

♦ The removal and installation is described for the left side of the
rear seat backing. The removal and installation for the right
side of the rear seat backing is made in an analogue manner.

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– Remove the fastening screws -3-, together with the bushings

-2- of the rear seat backing -1-.
– Remove the rear seat backing -1- from the backseat -4-.

2.3.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Before the assembly, clean the screw threads -3- and the re‐
spective bushings and apply chemical lock.

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– Tighten fastening screws -3- to (24 Nm) torque.

2.4 Rear seat (one-piece, with longitudinal adjustment) - assembly overview

1 - Rear seat backing (one-

piece, with longitudinal adjust‐
ment)
❑ Remove and install
⇒ page 172 .

Note

The seat and backing frameworks

are not sold separately

2 - Drawing handle
3 - Abdominal safety belt with
simple fastening
❑ Remove and install
⇒ page 50 .
4 - Double locking
❑ Remove and install
⇒ page 50 .

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2.5 Backing (one-piece, with longitudinal

adjustment) - removal and installation

2.5.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's backing lining and stuffing ⇒ page 205 .

Note

The lining do not need to be separated from the stuffing.

– Remove fastening screws -2- and -4-.

– Remove the fastening screws -3-, and remove the backing
framework -1- of the seat -5-.

2.5.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

Before the assembly, clean the screw threads and the respective nuts and apply new chemical lock.

– Screw on the fastening screws -2-, -2- and -4- with torque of
(25 Nm).

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2.6 Folding protection assembly on rear seat (one-piece, with longitudinal ad‐
justment) - assembly overview

1 - Unlocking handle
❑ Remove and install
⇒ page 174 .
2 - Metal protection cover
❑ 2 units
❑ Remove and install
⇒ page 174 .
3 - Plastic protection cover
❑ Remove and install
⇒ page 174 .
4 - Rear seat cushion structure
hook
5 - Rear seat bottom structure

Note

The seat and backing frameworks

are not sold separately

6 - Metal lock of the loop;

❑ Remove and install
⇒ page 174 .

2.7 Folding protection assembly on rear

seat (one-piece, with longitudinal adjust‐
ment) - remove and install

2.7.1 Removal

DANGER!

♦ The folding must be done with access by the side door

and, whenever as possible, by the right side.
♦ Locate the red elastic strap, housed under the seat, and
fit the hook of this strap in the passenger seat's headrest
bar, immobilizing the assembly.

– Fold the rear seat backrest.

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– Remove fastening screws -3- on the metal protection cover

-2-.
– Remover metal protection covers -2- from the rear seat cush‐
ion structure -1-.
– Remove fastening screws-3- from metal lock -2- located on
rear seat cushion structure -4-, as per detail -A-.

– Remove metal lock -2-, by removing it from unlock loop -1-, as

per detail -B-.

– Remove unlock loop -2- from the rear seat cushion structure
hook -1-.

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– Remove fastening screws -3- on the plastic protection cover

-2-.
– Remover plastic protection cover -2- from the rear seat cush‐
ion structure -1-.

2.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening screws -3- to (1.5 Nm) torque.

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– Install unlock loop -2- on the rear seat cushion structure hook
-1-.

Note

The small part of the unlock loop shall be placed towards the lug‐
gage compartment.

– Position metal lock -2- in the housing indicated for the unlock
loop -1-, as per detail -B-.

– Install metal lock -2- on the rear seat cushion structure -4-, as
per detail -A-.
– Tighten fastening screws -3- to (2.5 Nm) torque.

2.8 Rear seat (two-piece, with longitudinal adjustment) - assembly overview

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1 - Abdominal safety belt with

simple fastening
❑ Remove and install
⇒ page 54 .
2 - Unlocking handle
3 - Double locking
❑ Remove and install
⇒ page 54 .
4 - Two-piece rear seat back‐
ing framework

Note

The seat and backing frameworks

are not sold separately

5 - Lever for unlocking/folding

the backing
6 - Seat rail
❑ Remove and install
⇒ page 182 .

2.9 Backing (two-piece) - removal and in‐

stallation

2.9.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's backing lining and stuffing ⇒ page 208 .

Note

♦ The lining do not need to be separated from the stuffing.

♦ The bushing -5- is part of the seat structure -7-.

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Remove fastening screws -2- and -3-.

Remove the fastening screws -4-, and remove the backing frame‐
work -1- from the structure of the seat -7- and lining -6-.

2.9.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Before the assembly, clean the screw threads and apply new
chemical lock.

– Screw on the fastening screws -2-, -2- and -4- with torque of
(25 Nm).

2.10 Rear seat (split, with longitudinal adjustment - Europe only) - assembly
overview

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1 - Unlocking handle
2 - Single latch (right side)
❑ Remove and install
⇒ page 55 .
3 - Single latch (left side)
❑ Remove and install
⇒ page 55 .
4 - Unlocking lever for seat as‐
sembly
5 - Two-piece rear seat back‐
ing framework

Note

The seat and backing frameworks

are not sold separately

6 - Lever for unlocking/folding

the backing
7 - Seat rail
❑ Remove and install
⇒ page 182 .

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2.11 Backrest (split - Europe only) - assembly overview

1 - Split rear seat backrest

❑ Remove and install
⇒ page 181 .
2 - Screw
❑ 2 units.
❑ 25 Nm.
3 - Screw
❑ 2 units.
❑ 25 Nm.
4 - Screw
❑ 2 units.
❑ 25 Nm.
5 - Bushing
❑ It is an integral part of
the seat structure.
6 - Seat
7 - Seat framework
8 - Cup holder
❑ Remove and install
⇒ page 9 .

2.12 Backrest (split - Europe only)- remove

and install

2.12.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's backing lining and stuffing ⇒ page 210 .

Note

♦ The lining do not need to be separated from the stuffing.

♦ The bushing -5- is part of the seat structure -7-.

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– Remove fastening screws -2- and -3-.

– Remove the fastening screws -4-, and remove the backing
framework -1- of the seat -6-.

2.12.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

Before the assembly, clean the screw threads and apply new
chemical lock.

– Screw on the fastening screws -2-, -2- and -4- with torque of
(25 Nm).

2.13 Seat rail - removal and installation

2.13.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the seat's lining and stuffing ⇒ page 199 .

Note

The lining do not need to be separated from the stuffing.

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– Remove the nuts -1- (10 units).

– Remove the rail -4- from the seat`s structure-2-.
– Remove the abdominal safety belt with simple fastening -6-
and the double fastenings -3- from its respective studs -5-,
located in the seat rail's structure -4-.

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2.13.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Tighten fastening nuts -1- with (30 Nm) torque.

2.14 Seat backing stop (without longitudinal

adjustment) - assembly overview

Note

The removal and installation is described for the right side of the
rear seat. The removal and installation for the left side of the rear
seat is made in an analogue manner.

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1 - Riveted nut
❑ Install it using the tool
POP NUT rivet nut ap‐
plier -EQ 7422-
2 - Screw
❑ 3 units
❑ 7 Nm
3 - Rear seat backing without
longitudinal adjustment
4 - Stop (threaded pin)
❑ 12 Nm
5 - Bushing

2.15 Seat backing stop (without longitudinal

adjustment) - removal and installation

2.15.1 Removal

Note

It is not necessary to remove the lining of column „C“ to access

the rear seat's backing.

– Fold the seat backing.

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– Remove the stop (threaded pin) -4- along with the bushing
-5-.

2.15.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Remove the stop (threaded pin) -4- with torque of (12 Nm)..

2.16 Back seat head rest - assembly over‐

view

Note

The removal and installation is described for the right side of the
rear seat. The removal and installation for the left side of the rear
seat is made in an analogue manner.

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1 - Head rest
❑ Remove and install
⇒ page 187 .
2 - Head rest guide (bushing)
❑ Remove and install
⇒ page 188 .
3 - Front seat backing
❑ Remove and install
⇒ page 158 .
4 - Rear seat rest unlocking
button
❑ Remove and install
⇒ page 189 .

2.17 Rear seat head rest - removal and in‐

stallation

2.17.1 Removal
– Press the lock -2- according to detail -arrow-, and remove the
head rest -1- pulling it upwards.

2.17.2 Installation
The installation occurs in the reversal sequence of removal.

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2.18 Rear seat head rest guide - removal and

installation

2.18.1 Removal

Note

The removal and installation is described for the rear seat of the
right side. The removal and installation for the rear seat of the left
side is made in an analogue manner.

1 - Head rest guide (bushing)

with unlocking button
❑ In the side where there
is the unlocking button,
press the stuffing down
and unlock the lock
-arrow A- with a screw‐
driver.
❑ Remove the head rest
guide (bushing) -1-pull‐
ing it upwards.
2 - Head rest guide (bushing)
without unlocking button
❑ To remove it, press the
front part of stuffing
downwards and unlock
the lock -arrow B- with a
screwdriver .
❑ Remove the head rest
guide (bushing) -2-pull‐
ing it upwards.
3-

2.18.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

Before assembling, it is necessary to check the head rests guides

for damages and, if necessary, replace them.

2.19 Rear seat rest unlocking button - remov‐

al and installation

2.19.1 Removal
– Fold the seat backing.
– Remove the unlocking button base -1- of the fastening hook
according to detail -arrow- and remove it pulling upwards, un‐
plugging the rear seat backing assembly -2-.

Finish of the rear seat rest unlocking button:

– Remove the finishing with the aid of a Spatula -VW 037- or
Wedge -3409- , by pulling it upwards.

2.19.2 Installation
The installation occurs in the reversal sequence of removal.

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74 – Seat lining and upholstery

1 Linings, stuffing of front seats

1.1 Tools
Special tools and workshop equipment required
♦ Upholstery clip pliers -VAG 1634-

1.2 Front seat backing lining and stuffing -

removal and installation

Note

♦ During the removal and installation works, it is necessary to

consider some differences, depending on the version of the
respective equipment.
♦ The removal and installation is described for the front left seat.
The removal and installation for the front right seat is made in
an analogue manner.

1.2.1 Removal
– Remove the front seat ⇒ page 146 .
– Remove the front seat lining (with height adjustment)
⇒ page 155 .
– Remove the front seat backing ⇒ page 158 .

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– Disengage fastening profiles -3- from the seat framework -4-.

– Move the lining -1- upwards and in the the whole edging.
– Remove the clamps -2-.
– Remove the lining -1- with stuffing -5- from the seat framework
-4-.

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1.2.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ The clamps -2- are damaged in the removal. They must al‐
ways be replaced by clips -N 015 261.1- .
♦ Assemble the clamps -2- using the pliers for tapestry clamp -
VAG 1634- .

1.3 Lining and stuffing of the front backing - assembly overview

1 - Front seat back lining

❑ Remove and install
⇒ page 193
2 - Stuffing wire
3 - Stuffing clamp
4 - Clip
5 - Lid
6 - Activation lever
7 - Fitting ruler

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1.4 Front seat backing lining and stuffing -

removal and installation

Note

The removal and installation is described for the front left seat
backing. The removal and installation for the front right seat back‐
ing is made in an analogue manner.

1.4.1 Removal
– Remove the front seat ⇒ page 146 .
– Remove the front seat covers ⇒ page 155 .
– Remove the front seat backing ⇒ page 158 .
– Remove the head rest guide bushings ⇒ page 165 .
– Remove the activating lever -3- of backing unlocking.
– Remove the lid -2-.

Note

In assembly, replace the activation lever -3- and the respective

clamp -1- when they are damaged.

– Unplug the fitting ruler -2- in the lower part of the front seat
backing.
– Unplug the stuffing wires -1-.

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– Move the lining -1- to access the clamps -6- and behind the
stretching wires -3-.
– Remove the clamps -6-.
– Unplug the stretching wires -3- (2 units) and the left and right
fastening belt -4-.
– Remove the lining -1- with stuffing -5- of the front seat backing
framework -2-.
– Remove the stuffing -5- of the front seat backing framework
-2-.

1.4.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

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Note

♦ The clamps -6- are damaged in the removal. They must al‐
ways be replaced by clips -N 015 261.1- .
♦ Assemble the clamps -6- using the pliers for tapestry clamp -
VAG 1634- .

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2 Front seat heating

2.1 Driver / passenger seat cushion heating

-Z6 / Z8- - remove and install

2.1.1 Removal
– Remove the seat ⇒ page 146
– Remove the backrest ⇒ page 158
– Remove the seat cushion lining ⇒ page 190 .
– Disengage seat cushion heating connector from the connector
support under the seat.
– Remove the Driver / passenger seat cushion heating -Z6 / Z8-
-1- from the filling -2-.
– Disconnect the harness through the seat filling opening.

2.1.2 Installation
The installation occurs in the reversal sequence of removal.

2.2 Driver / passenger seat backrest heat‐

ing -Z7 / Z9- - remove and install

2.2.1 Removal
– Remove the seat ⇒ page 146
– Remove the backrest ⇒ page 158
– Remove the seat backrest lining ⇒ page 192 .

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– Disconnect the harness -1- through the opening -2- at the

central section of the filling -3- and remove the Driver / pas‐
senger seat backrest heating -Z7 / Z9- -4-.

2.2.2 Installation
The installation occurs in the reversal sequence of removal.

2.3 Lining and stuffing of the front seat head

rest - removal and installation

Note

The removal and installation is described for the front left seat
head rest. The removal and installation for the front right seat
head rest is made in an analogue manner.

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2.3.1 Removal
– Remove the front seat's head rest ⇒ page 186 .
– Unplug the fitting ruler -1- in the lower part of the front seat
head rest.
– Remove the lining -2- with stuffing -3- of the front seat head
rest framework.

2.3.2 Installation
– The installation occurs in the reversal sequence of removal.

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3 Linings and stuffing of front seats

3.1 Tools
Special tools and workshop equipment required
♦ Upholstery clip pliers -VAG 1634-

3.2 Lining and stuffing of back seat (without longitudinal adjustment) - assembly
overview

1 - Rear seat bottom lining

❑ Remove and install
⇒ page 200 .
2 - Rear seat bottom stuffing
❑ Remove and install
⇒ page 200 .
3 - Rear seat framework (with‐
out longitudinal adjustment)
4 - Lining fitting ruler
5 - Back seat lining cable
6 - Back seat lining cable fas‐
tening clamp
❑ -N 015 261.1- .
7 - Stuffing wire
8 - Stuffing clamp
❑ -N 015 261.1- .

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3.3 Lining and stuffing of back seat (without

longitudinal adjustment) - removal and
installation

3.3.1 Removal
– Remove the back seat ⇒ page 167 .

– Unplug the fitting ruler -4- of the lining-1- in the lower part of
the seat.
– Untie the cables -5- in the framework's left and right side, as
well as removing the clamps -6- of lining fastening-1-.
– Pull the lining away -3- to gain access to the clamps -1-
– Remove the clamps -8- and remove the lining -1- from the
stuffing -2-.
– Remove the stuffing -2- from the seat's structure-3-.

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3.3.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ The clamps -6- and -8- are damaged in the removal. They
should always be replaced with clamps -N 015 261.1- .
♦ Assemble the clamps -6- and -8- using the pliers for tapestry
clamp -VAG 1634- .

3.4 Lining and stuffing of back seat (with longitudinal adjustment) - assembly
overview

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1 - Rear seat bottom lining

❑ Remove and install
⇒ page 203 .
2 - Rear seat bottom stuffing
❑ Remove and install
⇒ page 203 .
3 - Rear seat framework with
longitudinal adjustment
4 - Lining fitting ruler
5 - Back seat lining cable
6 - Back seat lining cable fas‐
tening clamp
❑ -N 015 261.1- .
7 - Stuffing wire
8 - Stuffing clamp
❑ -N 015 261.1- .

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3.5 Lining and stuffing of back seat (with

longitudinal adjustment) - removal and
installation

3.5.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the loop's metallic lock ⇒ page 174
– Unplug the fitting ruler of the lining-4- in the lower part of the
seat.
– Untie the cables -5- in the framework's left and right side, as
well as removing the clamps -6- of lining fastening-1-.
– Pull the lining away -3- to gain access to the clamps -1-
– Remove the clamps -8- and remove the lining -1- from the
stuffing -2-.
– Remove the stuffing -2- from the seat's structure-3-.

3.5.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ The clamps -6- and -8- are damaged in the removal. They
should always be replaced with clamps -N 015 261.1- .
♦ Assemble the clamps -6- and -8- using the pliers for tapestry
clamp -VAG 1634- .

3.6 Rear seat cushion lining and filling (with longitudinal adjustment and cup
holder - Europe only) - assembly overview

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1 - Rear seat bottom lining

❑ Remove and install
⇒ page 204
2 - Rear seat bottom stuffing
❑ Remove and install
⇒ page 204
3 - Rear seat framework with
longitudinal adjustment
4 - Lining fitting ruler
5 - Back seat lining cable
6 - Back seat lining cable fas‐
tening clamp
❑ -N 015 261.1- .
7 - Cup holder
❑ Remove and install
⇒ page 9
8 - Stuffing wire
9 - Stuffing clamp
❑ -N 015 261.1- .

3.7 Rear seat cushion lining and filling (with

longitudinal adjustment and cup holder -
Europe only) - remove and install

3.7.1 Removal
– Remove the back seat ⇒ page 167 .

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General body repairs, interior - Edition 04.2011

– Remove cup holder ⇒ page 9 .

– Unplug the fitting ruler of the lining-4- in the lower part of the
seat.
– Untie the cables -5- in the framework's left and right side, as
well as removing the clamps -6- of lining fastening-1-.
– Pull the lining away -1- to gain access to the clamps -9-
– Remove the clamps -9- and remove the lining -1- from the
stuffing -2-.
– Remove the stuffing -2- from the seat's structure-3-.

3.7.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ The clamps -6- and -9- are damaged in the removal. They
should always be replaced with clamps -N 015 261.1- .
♦ Assemble the clamps -6- and -9- using the pliers for tapestry
clamp -VAG 1634- .

3.8 Lining and stuffing of the back seat (one-piece) backing - assembly over‐
view

3. Linings and stuffing of front seats 205

 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

1 - Back seat head rest

❑ Remove and install
⇒ page 186 .
2 - Head rest guide (bushing)
❑ Remove and install
⇒ page 188 .
3 - Rear seat back lining
❑ Remove and install
⇒ page 206 .
4 - Stuffing wire
5 - Stuffing clamp
❑ -N 015 261.1-
6 - Rear seat back stuffing
❑ Remove and install
⇒ page 206 .
7 - Fastening clip of the safety
belt
8 - Back seat backing lining ca‐
ble fastening profiles
9 - Screw
❑ 2 units.
❑ 24 Nm.
10 - One-piece rear seat back‐
ing framework
11 - Screw
❑ 4 units.
❑ 2.5 Nm.
12 - Cap
❑ Remove and install
⇒ page 189 .
13 - Rear seat rest unlocking button
❑ Remove and install ⇒ page 189 .

3.9 Lining and stuffing of the back seat (one-

piece) backing - removal and installation

3.9.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the back seat head rests ⇒ page 186 .
– Remove the back seat head rests guides ⇒ page 188 .
– Remove the fastening screws -11- and remove the fastening
clip from the safety belt -7-.

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General body repairs, interior - Edition 04.2011

– Remove the unlocking button and the back seat finish

⇒ page 189 .
– Unplug the lining fastening profiles -8- in the whole border in
the rear side of the backing.
– Pull the lining away -3- to gain access to the clamps -5-
– Remove the clamps -5- and remove the lining -3- of the back‐
ing stuffing -6-.
– Remove the backing stuffing -6- from the backing struc‐
ture-10-.

3.9.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install the safety belt's fastening clip -7- and fasten the fas‐
tening screws -11- with torque of (2.5 Nm).

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 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

Note

♦ The clamps -5- are damaged in the removal. They should al‐
ways be replaced with clamps -N 015 261.1- .
♦ Assemble the clamps -5- using the pliers for tapestry clamp -
VAG 1634- .

3.10 Lining and stuffing of the back seat (two-piece) backing - assembly overview

1 - Two-piece rear seat back‐

ing framework (right side)
2 - Two-piece rear seat back‐
ing framework (left side)
3 - Screw
❑ 4 units.
❑ 2.5 Nm.
4 - Fastening clip of the safety
belt
5 - Back seat backing lining ca‐
ble fastening profiles
6 - Back seat
7 - Stuffing wire
8 - Stuffing clamp
❑ -N 015 261.1-
9 - Two-piece rear seat back‐
ing stuffing (left side)
❑ Remove and install
⇒ page 209 .
10 - Two-piece rear seat back‐
ing lining (left side)
❑ Remove and install
⇒ page 209 .
11 - Two-piece rear seat back‐
ing stuffing (right side)
❑ Remove and install
⇒ page 209 .
12 - Two-piece rear seat back‐
ing lining (right side)
❑ Remove and install
⇒ page 209 .
13 - Head rest guide (bushing)
❑ Remove and install ⇒ page 188 .

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 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

14 - Back seat head rest (right side)

❑ Remove and install ⇒ page 186 .

3.11 Lining and stuffing of the back seat (two-

piece) backing - removal and installation

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

3.11.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the back seat head rests ⇒ page 186 .
– Remove the back seat head rests guides ⇒ page 188 .
– Remove the fastening screws -3- and remove the fastening
clip from the safety belt -4-.
– Unplug the lining fastening profiles -5- in the whole border in
the rear side of the backing.
– Pull the lining away -3- to gain access to the clamps -10-.
– Remove the clamps -8- and remove the lining -10- of the back‐
ing stuffing -9-.
– Remove the backing stuffing -9- from the backing struc‐
ture-2-.

3.11.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:
– Install the safety belt's fastening clip -4- and fasten the fas‐
tening screws -3- with torque of (2.5 Nm).

3. Linings and stuffing of front seats 209

 Fox 2004 ➤
General body repairs, interior - Edition 04.2011

Note

♦ The clamps -8- are damaged in the removal. They should al‐
ways be replaced with clamps -N 015 261.1- .
♦ Assemble the clamps -8- using the pliers for tapestry clamp -
VAG 1634- .

3.12 Rear seat backrest lining and filling (split - Europe only) - assembly overview

1 - Two-piece rear seat back‐

ing framework (right side)
2 - Two-piece rear seat back‐
ing framework (left side)
3 - Back seat backing lining ca‐
ble fastening profiles
4 - Rear seat cushion with cup
holder
5 - Stuffing wire
6 - Stuffing clamp
❑ -N 015 261.1-
7 - Two-piece rear seat back‐
ing stuffing (left side)
❑ Remove and install
⇒ page 211 .
8 - Two-piece rear seat back‐
ing lining (left side)
❑ Remove and install
⇒ page 211 .
9 - Two-piece rear seat back‐
ing stuffing (right side)
❑ Remove and install
⇒ page 211 .
10 - Two-piece rear seat back‐
ing lining (right side)
❑ Remove and install
⇒ page 211 .
11 - Head rest guide (bushing)
❑ Remove and install
⇒ page 188 .
12 - Back seat head rest (right
side)
❑ Remove and install ⇒ page 186 .

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General body repairs, interior - Edition 04.2011

3.13 Rear seat backrest lining and filling (split

- Europe only) - removal and installation

Note

The removal and installation is described for the left side of the
vehicle. The removal and installation for the right side of the ve‐
hicle is made in an analogue manner.

3.13.1 Removal
– Remove the back seat ⇒ page 167 .
– Remove the back seat head rests ⇒ page 186 .
– Remove the back seat head rests guides ⇒ page 188 .
– Unplug the lining fastening profiles -3- in the whole border in
the rear side of the backing.
– Pull the lining away -8- to gain access to the clamps -6-
– Remove the clamps -6- and remove the lining -8- from the
backing stuffing -7-.
– Remove the backing stuffing -7- from the backing struc‐
ture-2-.

3.13.2 Installation
The installation occurs in the reversal sequence of removal, ob‐
serving the following instructions:

Note

♦ The clamps -6- are damaged in the removal. They should al‐
ways be replaced with clamps -N 015 261.1- .
♦ Assemble the clamps -6- using the pliers for tapestry clamp -
VAG 1634- .

04.11

3. Linings and stuffing of front seats 211