Polo Mk4: Body
Also for this vehicle: Polo Mk3, Polo Mk5.
Steering & suspension
Body & interior
Engine
General
Transmission
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
General body repairs, exterior381 pages
Body front33 pages
Front panel13 pages
Wing10 pages
Lower noise insulation in the engine compartment3 pages
Bonnet, flaps, cab, central locking55 pages
Bonnet22 pages
- Tools
- Front bonnet - assembly overview
- Front bonnet shock absorber (? 2006) - remove and install
- Bonnet - adjust
Front bonnet latch operating cable - remove and install4 pages
- Front bonnet latch - Assembly overview
Rear door - Hatch15 pages
- Assembly overview
- Rear door shock absorber - remove and install
- Rear door shock absorber - make useless for discarding
- Rear door - adjust
Rear door lock - remove and install3 pages
- Rear door latch cylinder - assembly overview
- Rear door lock cylinder (central locking) - assembly overview
Rear door latch cylinder - disassemble and assemble0 pages
- Disassemble
- Assemble
Rear door - Sedan15 pages
- Rear door - Assembly overview
- Rear door shock absorber - remove
- Rear door - adjust
- Cylinder housing of the lock with symbol (without central locking) - remove and install
- Rear door lock (without central locking) - remove and install
- Rear door lock (with central locking) - remove and install
- Cylinder housing of the lock with symbol (with central locking) - remove and install
- Rear door latch activation handle - assembly overview
- Rear door latch activation handle (without central locking) - remove and install
- Rear door latch activation handle (with central locking) - remove and install
- Rear door latch cylinder - assembly overview
Fuel reservoir nozzle compartment and lid set3 pages
Front door, central locking39 pages
Front door30 pages
Central locking9 pages
Rear door,sliding door,wing doors,central locking › Rear door24 pages
Sliding roof › Sliding / tilting sunroof27 pages
- Operation
- Sliding / tilting roof with glass pane - assembly overview
- Glass pane for sliding / tilting sunroof - height adjustment
- Cover packing - adjust
- Cover packing - replace
- Air deflector - remove
- Sliding sunroof movement control unit J245 - remove
- Sunroof sliding adjustment E139 - remove
- Sliding sunroof drive motor V1 - remove
- Sliding sunroof drive motor V1 (zero position) - adjust
- Parallelism - check
- Parallelism - adjust
- Sliding guide - remove
- Guide with steel cable - remove
Bumper29 pages
Front bumper13 pages
- Tools
- Front protector - repair
- Front protector (? 06.06) - assembly overview
- Front protector (? 2006) - remove and install
- Protector support (? 2006) - assembly overview
- Front protector (2007 ?) - assembly overview
- Front protector additional components (2007 ?)
- Front protector support (2007 ?) - assembly overview
- Front bumper spoiler - Blue Motion - remove and install
Rear bumper - hatch9 pages
Rear bumper - sedan7 pages
Glazing/window mechanism68 pages
Glued glasses39 pages
- Tools
- Auxiliary materials for the Brazilian market
- Auxiliary materials for the export market
- Matching table
- Repair the windscreen
- Labels for engraving the chassis number on glass - replacement
- Windscreen - Assembly overview
- Windscreen - remove
- Windscreen - install
- Side glass (hatch) - assembly overview
- Undamaged side glass (hatch) - remove
- Damaged side glass (hatch) - remove
- Side glass (hatch) - install
- Rear door glass - assembly overview
- Rear door glass (undamaged) - remove
- Rear door glass (damaged) - remove
- Rear door glass - install
- Undamaged rear door glass - remove
- Rear door glass (damaged) - remove
- Rear door glass - install
- Prepare the undamaged glass for glass assembly
Prepare the new glass with encapsulation for glass assembly2 pages
Prepare the new glass without encapsulation for glass assembly4 pages
- Prepare the body flange for glass assembly
- Rear window (sedan) - assembly overview
- Undamaged rear window (Sedan) - remove
- Rear window - install
- Damaged rear window (sedan) - remove
- New rear window (sedan) - prepare a new glass for assembly
- Assembly instructions
- Minimum drying time
- Repair damage to painting
- Cleaning in case of dirt due to the adhesive
Door windows29 pages
- Front door window - assembly overview
- Front door window - remove and install
- Front door window - adjust
- Rear door window - assembly overview
- Rear door window - remove
- Rear door window - install
Power window drive mechanism (automatic opening and closing system) with force limiter4 pages
- Re-establish the operation after the force limiting activation
Power window drive mechanism motor - remove and install4 pages
- Rear door window (sedan) - assembly overview
- Fixed rear door window (sedan) - remove
Exterior equipment106 pages
Wheel case protector6 pages
External rear-view mirror18 pages
Front grille17 pages
Trims23 pages
- Door trims - remove and install
- External longitudinal member lining (front door - GT) - replace
Measures to position the inscriptions on the rear door3 pages
- "CONFORTLINE” and "SPORTLINE” inscriptions - replace
- "BlueMotion” inscription on rear lid - replace
- Lower longitudinal member trim (Blue Motion) - assembly overview
Lower longitudinal member trim (Blue Motion) - remove and install8 pages
Spoiler - Hatch27 pages
Rear spoiler - Sedan13 pages
Rear spoiler (? 07.07) - remove and install6 pages
Rear spoiler (08.07 ?) - remove and install6 pages
General body repairs, interior267 pages
Interior equipment52 pages
Internal rearview mirror11 pages
- Internal rear-view mirror with automatic anti-glare
- Internal rear-view mirror (without rain sensor) - remove and install
- Internal rearview mirror support plate - glue
Internal rear-view mirror (with rain sensor) - remove and install4 pages
Mirror fastening support (with rain sensor) - install2 pages
- Rain sensor and mirror - install
Object compartment, covers and lids35 pages
Passenger protection73 pages
safety belts - general information4 pages
safety belts20 pages
Lower fastening point of the front safety belt - remove and install3 pages
Rear safety belts15 pages
Airbag26 pages
- Installation locations - assembly overview
- Safety measures for Airbag works
Airbag ignition devices after an accident - replacing3 pages
Ignition device for driver's airbagN95 (steering wheel with 3 spokes) - removal and installation3 pages
Ignition device for driver's airbagN95 (multifunction steering wheel) - removal and installation3 pages
Ignition device for driver's airbagN95 (steering wheel with 4 spokes) - removal and installation3 pages
Connector of the airbag coil and return spring with sliding ringF138 - remove and install3 pages
Trim, noise insulation71 pages
Instrument panel11 pages
Door lining13 pages
Lining of columns and sides25 pages
Linings of the luggage compartment5 pages
Roof lining11 pages
Noise insulation6 pages
Seat frames50 pages
Front seats32 pages
- Tools
Lower front seat cushion cover (without height adjustment)4 pages
Lower front seat cushion cover (with height adjustment)4 pages
Front seat head rest - assembly overview2 pages
- Installation
Rear seats18 pages
Seat padding, covers21 pages
Linings, stuffing of front seats9 pages
Linings and stuffing of front seats12 pages
- Rear seat cushion lining and filling (bench) - assembly overview
- Lining and stuffing of the back seat (one-piece) backing - assembly overview
Lining and stuffing of the back seat (one-piece) backing - removal and installation3 pages
- Lining and stuffing of the back seat (two-piece) backing - assembly overview
Lining and stuffing of the back seat (two-piece) backing - removal and installation3 pages
Chemicals Manual › Technical data310 pages
- Introduction
List of Suppliers39 pages
- 3 M do Brasil
- Alba Química Ind. Com. Ltda
- Aletron Produtos Químicos Ltda
- Brascola Ltda
- Castrol Brasil Ltda
- Cia Brasileira de Petróleo Ipiranga
- Colauto - Adesivos e Massas Ltda
- Cremer S.A. Prod. Texteis e Cirúrgicos
- Dow Corning do Brasil Ltda
- Dow Automotive System
- Du Pont S/A
- Elf Lubrificantes do Brasil
- Esso Brasileira de Petróleo Ltda
- Formiquímica Com. e Repres. de Produtos Químicos Ltda
- Gratec System Industria de Produtos Químicos Ltda
- Henkel do Brasil Ltda
- Indaco Industria e Comércio Ltda
- Klüber Lubrification Lubrificantes Especiais Ltda
- Loctite Brasil Ltda
- Lumobrás Imp. Com. Ind. Ltda
- ExxonMobil do Brasil Ind. Com. Ltda
- Motul Synthetic Lubricants
- Nippondenso Compressores Ltda
- Pentosin do Brasil Ltda
- Petrobras Distr. S/A
- Promax Prods. Máximos S/A Indústria e Comércio
- Repsol - YPF S.A. Divisão Lubrificantes Brasil
- Quaker Chemical Industria e Comércio Ltda
- Shell Brasil S/A
- Sika S/A
- Solplás - Ind. de Plásticos Ltda
- Solvay Química
- Texaco Brasil S/A Produtos de Petróleo
- Three Bond do Brasil Ind. e Com. Ltda
- Total Lubrificantes Brasil Ltda
- Tutela Lubrificantes S/A
- Valvoline Lubrificantes Internacionais Ltda
- Wal Química S/A
List of authorized products110 pages
- Assembly Sticker
- Adhesive for polyurethane and polypropylene
- Resin adhesive
- Polyurethane-based sealing adhesive
- Instant adhesive
- Adhesive for sealing gaskets
- Permanent adhesive
- Adhesive for packings and linings
- Polyurethane adhesive
- Polyurethane adhesive
- Adhesive with 2 components
- Epoxy adhesive with 2 components
- Sealing adhesives for engines
- High-resistance locking adhesive
- Low viscosity lock adhesive
- Locking adhesive
- Locking adhesive for mechanical seals
- Medium torque locking adhesive
- Adhesive for plastic cap gaskets
- Metal-glass adhesive
- Sealing adhesive
- 2-component adhesive
- Activating agent for pre-laminated glass
- Additives for coolants - G11
- Coolant additive - G12 Plus
- Additive for the windscreen/rear window washer reservoir
- Additives for petrol
- Silicone rubber
- Filling and acoustic isolation foam
- Polyurethane adhesive tape
- Polyurethane adhesive tape
- Cotton tape
- Self-adhesive PVC tape
- Transferable adhesive tape
- Sealing tape
- Double-sided adhesive tape
- Double-sided acrylic foam adhesive tape
- Medium density double-sided adhesive tape
- Hydraulic brake fluid (DOT 4)
- Automatic transmission fluid
- Refrigerant gas - R134a
- Multi-purpose grease
- Semi-fluid grease
- Multi-purpose grease
- Multi-purpose grease
- Multi-purpose grease
- Special lubrification grease
- Lubricating grease
- Complex grease
- Graphite grease
- Grease for front wheel cylinder support guide pin
- Grease for transmission side seals
- Lubricating grease
- Grease for electrical contacts
- Polyurea grease
- High temperature grease
- Temperature resistant grease
- Lubricating grease
- Multi-purpose grease
- Silicone based grease
- Windscreen adhesive set
- Windscreen adhesive set
- Glass-metal adhesive set
- Glass adhesion kit
- Lithium-based lubricant
- Addhesive paste and grey sealant
- Adhesive material for glass
- Sealing paste
- Adhesive material for glass
- Sealing paste for bodywork
- Silicone paste
- Mouldable paste for caulking
- Sealing paste
- Lubricating paste for high temperatures
- Lubricating paste for constant velocity joints
- Sealing paste
- Sealing paste
- Sealing paste
- Sealing paste
- Sealing paste
- Paste for bucket protection
- Sealing paste for engines
- Sealing paste
- Sealing paste for engine
- Nyogel
- Liquid sealant
- Lubricating oil for engines (Petrol, Ethanol, Totalflex and GNV - VW 501 01 and VW 502 00)
- Lubricating oil for diesel engines - VW 505 00
- Lubricating oil for diesel engines - VW 505 01
- Lubricating oil for mechanical transmission and steering box - SAE 90, MIL-L-2105B, API-GL5
- Lubricating oil for mechanical transmission - SAE 80, MIL-L-2105, API-GL4
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Special oil
- Oil for mechanical transmission
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for mechanical transmission - SAE 75W90
- Lubricating oil for power steering
- Lubricating oil for automatic transmission and power steering
- Lubricating oil for the automatic transmission differential - SAE 75 W 90
- High performance oil for the clutch
- VW ATF oil for power steering
- VW ATF oil for power steering
- ATF oil for automatic transmissions
- VW ATF oil for power steering
- Oil for gear selection mechanism
- Air conditioning compressor oil - R 134a
- Oil for the air conditioning compressor
- Universal oil
- Lubricating oil for assembly
- White lubricating grease
- Moly grease
- Lubricating grease
- Molybdenum bisulphate lubricating grease
- Copper grease
- High temperature paste
- Primer
- Glass primer
- Adhesive remover
- Cleaning remover
- Corrosive paste
- Odourless solvent
- Cleaning solution
- Engine leak detection spray
- Cylinder lubricating spray
- Primer for polyurethane surface
- Adhesive sealant
- Elastic sealand
- Mixing tube
- Liquid sealant
- Silicone sealant for engines
- Sealant for exhaust connections
- Teflon thread sealant
Work Instructions for Handling Chemicals5 pages
General considerations4 pages
Repair Group 10 - Cylinders, engine block, support, protector5 pages
Repair Group 13 - Crankshaft, pistons4 pages
Repair Group 15 - Cylinder head, valve control mechanism6 pages
- Intermediate shaft seal - lubricate for assembly
- Camshaft valve bearing cover (1st and 5th) - Seal
- Cylinder head sealing gasket - glue
- Lower rear studs fastening the head - rear stud (crankshaft) / lower front studs (flywheel) - Seal
- Cylinder head cover - seal
- Cylinder head cover - seal
- Cylinder head cover - seal
Repair Group 17 - Lubrication system4 pages
Repair Group 19 - Cooling system3 pages
Repair Group 20 - Supply system - tank, fuel pump5 pages
Repair Group 30 - Clutch - control system16 pages
- Clutch pedal bung - lubricate
- Clutch control cable - lubricate
- Clutch fork, contact with bearing - lubricate
- Clutch fork bungs - lubricate
- Butterfly nut for clutch control cable adjustment - lubricate
- Sealing ring for the de-clutch bearing guide - lubricate for assembly
- Clutch cable - lubricate
- Clutch fork and clutch operating lever - lubricate
- Clutch pedal fastening - lubricate
- Clutch operating cable - lubricate
- Primary shaft splines - lubricate
- Clutch pedal / clutch pedal bung - lubricate
- Pedal support - seal
- Clutch fork contact with the hydraulically activated cylinder of the transmission clutch - lubricate
- Fastening flange for the hydraulically activated slave cylinder of the clutch - seal
Repair Group - 34 - Drive, housing15 pages
- Linkage rod, front/rear section - lubricate
- Gearshift lever bearing
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Manual transmission - Fill / top up level
- Plastic bungs for the linkage rod coupling system / linkage rod / supports (on the transmission) - lubricate
- Gearshift lever guide plate - lubricate
- Rubber shim for the clutch compartment cover - glue
- Clutch compartment cover - seal
- Linkage rod bellows for the gearshift lever assembly - fasten / seal
- Junction of cases and differential cover housing (gearbox / differential) - seal
- Gearshift lever handle - fasten
- Fastening screw for the rear support of the transmission cushion - seal
- Transmission cushion - lubricate
- Gear selection mechanism - fill up
- Electric connectors of the gear selection mechanism - apply nyogel
Repair Group 35 - Gears and shafts3 pages
Repair Group - 37 - Drive, housing2 pages
- Planetary gear box (automatic transmission) - Fill / top up oil level
- Planetary gear box (automatic transmission) - Fill / top up oil level
- Planetary gear box (automatic transmission) - Fill / top up oil level
Repair Group - 39 - Transmission shafts, differential5 pages
Repair Group - 40 - Front suspension11 pages
Repair Group - 46 - Brakes - Mechanical systems7 pages
Repair Group - 47 - Brakes - Servo brake hydraulic system4 pages
Repair Group - 48 - Steering5 pages
- Oil tank for the power steering system - Fill / top up oil level
- Oil tank for the power steering system - Fill / top up oil level
- Steering box - Fill / top up level
- Steering box mechanism - lubricate
- Adapter (sleeve) for the upper steering shaft - lock
Repair Group - 53 - Body - Rear section3 pages
Repair Group - 57 - Front doors / components / central lock5 pages
Repair Group - 58 - Rear doors / components3 pages
Repair Group - 64 - Windscreens, windows, window mechanism11 pages
- Door window activation mechanism - lubricate
- Vent window latch - lubricate
- Front door glass support - lubricate
- Front door window activation mechanism - lubricate
- Window crank fastening screw - lock
- Windscreen, side window glass and rear window glass - glue
- Windscreen, side window glass and rear window glass - seal
- Glass - engrave chassis number
- Front and rear door window guide groove - glue
- Vent window - seal
Repair Group - 70 - Lining/insulation5 pages
Repair Group - 72 - Seat framework3 pages
Repair Group - 87 - Air conditioning4 pages
Repair Group - 92 - Windscreen, rear window and headlight wiper and washer3 pages
Repair Group - 94 - Switches, lights, and external bulbs2 pages
Repair Group - 97 - Cables and electrical harnesses2 pages
Painting Manual › Technical data237 pages
- Introduction
Safety at the Working Area18 pages
Colors145 pages
1995 line - Domestically manufactured vehicles4 pages
1996 line - Domestically manufactured vehicles4 pages
1997 line - Domestically manufactured vehicles4 pages
1998 line - Domestically manufactured vehicles4 pages
1999 line - Domestically manufactured vehicles4 pages
2000 line - Domestically manufactured vehicles4 pages
2001 line - Domestically manufactured vehicles4 pages
2002 line - Domestically manufactured vehicles4 pages
2003 line - Domestically manufactured vehicles4 pages
2004 line - Domestically manufactured vehicles4 pages
2005 line - Domestically manufactured vehicles4 pages
2006 line - Domestically manufactured vehicles4 pages
2007 line - Domestically manufactured vehicles4 pages
2008 line - Domestically manufactured vehicles4 pages
2009 line - Domestically manufactured vehicles4 pages
2010 line - Domestically manufactured vehicles4 pages
2011 line - Domestically manufactured vehicles4 pages
2012 line - Domestically manufactured vehicles4 pages
Special colors22 pages
Special colors21 pages
- Fox Blackfox 2012
- Fox Crossfox
- Fox Crossfox 2012 ?
- Fox Extreme
- Fox Silverfox 2012
- Gol Rallye
- Vintage Gol
- Golf GT
- Golf Silver Edition
- Golf Black Edition 2011
- Silver series Kombi
- Parati Track and Field (Generation IV)
- Parati Surf
- Parati Titan
- Saveiro Crossover (generation III)
- Saveiro Crossover (generation IV)
- Saveiro Titan
- Saveiro Surf
- Saveiro Trooper 2010 ?
- Saveiro Cross 2010 ?
Complements15 pages
Repainting12 pages
Paint repair on steel plates and zinc-coated steel plates4 pages
Paint repair on plastic parts2 pages
- Spray guns and their use
- Paint dryers by irradiation
- Dryers based on air insufflation (water-based painting)
Application of anti-corrosion fluid8 pages
Body Repair - General Information › Technical data86 pages
Safety indications24 pages
- Removal of components
- Battery, welding works
Electronic control units2 pages
- Painting, windows, stuffing, trims
- Fuel tank or fuel line
- Airbag System - Safety measures for works
Ignition devices of the airbag after an accident - what must be replaced3 pages
- Safety standards for belt tensioner
- Works on vehicles with belt tensioner
- Repair, alignment and/or body works on vehicles with airbag
- Removal of front seats with side airbag
Explanation of symbols10 pages
Tools for body repair10 pages
Glued parts of the body12 pages
Repair solutions on partial replacement6 pages
Anti-corrosive protection measures4 pages
Materials for anti-corrosive protection before welding2 pages
- Anti-corrosive protection and special guarantee against perforation due to corrosion
Indications on residue elimination5 pages
Steel panels repair11 pages