VW Phaeton General Body Repairs Exterior

Service
Workshop Manual
Phaeton 2003 ➤
General body repairs, exterior
Edition 07.2010
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
Phaeton 2003 ➤
General body repairs, exterior - Edition 07.2010
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Fitting locations of adaptive cruise control senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Assembly overview - lock carrier, service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Assembly overview - lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Removing and installing lock carrier with add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Assembly overview - lock carrier attaching parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 Installation instructions for longitudinal members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Installation instructions for vehicles with adaptive cruise control . . . . . . . . . . . . . . . . . . . . 10
1.10 Removing and installing ACC senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Assembly overview - front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Removing and installing front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Front wing - bolting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Assembly overview - noise insulation in vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . 18
3.3 Assembly overview - noise insulation in vehicles up to 06.2010 . . . . . . . . . . . . . . . . . . . . 19
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Assembly overview - bonnet of vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Assembly overview - bonnet of vehicles up to 06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Service position for bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Removing and installing insulation of vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . . . 25
2.7 Removing and installing insulation of vehicles up to 06.2010 . . . . . . . . . . . . . . . . . . . . . . 25
3 Lock and release components of bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Assembly overview - bonnet lock and release components of vehicles up to 05.2010 . . . . 28
3.2 Assembly overview - bonnet lock and release components of vehicles up to 06.2010 . . . . 29
3.3 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Adjusting bonnet and bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 Detaching Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6 Removing and installing release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2 Assembly overview - aluminium hinge and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Removing and installing hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4 Assembly overview - steel hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5 Removing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.7 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.8 Basic adjustment of rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.9 Adjusting striker plate with lock cover removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.10 Adjusting striker plate with lock cover installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.11 Adjusting dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Lock parts with servo rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Contents i
Phaeton 2003 ➤
5.1 Assembly overview - lock parts with servo rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Removing and installing lock cylinder carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Lock parts with basic rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Assembly overview - lock parts with basic rear lid opener . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Removing and installing lock cylinder carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 Removing and installing lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Assembly overview - front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.6 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.7 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.8 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.9 Door handle with (Keyless Entry) cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.11 Assembly overview - door power latching motor (V 278) . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.12 Door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.13 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.14 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.15 Door insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.16 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.17 Adapting ignition keys to remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.18 Removing and installing batteries for folding main key with remote control system . . . . . . 75
2.19 Assembly overview - batteries for main key (foldable) with remote control, vehicles from
01.2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.20 Removing and installing batteries for folding main key with remote control system, vehicles
from 01.2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.21 Assembly overview - batteries for main key (foldable) with remote control, vehicles from
06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.22 Removing and installing batteries for folding main key with remote control system, vehicles
from 06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.2 Assembly overview - rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.5 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.6 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.7 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.8 Door handle with (Keyless Entry) cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.9 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.10 Assembly overview - door power latching motor (V 278) . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.11 Door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.12 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
ii Contents
Phaeton 2003 ➤
2.13 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.14 Door insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.15 Installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1 Sunroof with glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.4 Removing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.5 Installing sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.6 Adjusting height of sliding/tilting sunroof glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.7 Checking parallel running of glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Adjusting parallel running of glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.9 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.10 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.11 Adjusting wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.12 Removing and installing sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.13 Adjusting parallel running of sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.14 Removing and installing sliding/tilting sunroof drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.15 Adjusting drive for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.16 Removing and installing drive for sliding headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.17 Removing and installing wind deflector drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.18 Removing and installing sliding/tilting sunroof automatic preselector . . . . . . . . . . . . . . . . 114
1.19 Removing switches for sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.20 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.21 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.22 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.23 Adapting components of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.24 Coding sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Remove sliding/tilting sunroof with solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.4 Removing sliding/tilting sunroof solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.5 Installing sliding/tilting sunroof solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.6 Adjusting sliding/tilting sunroof solar panel height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.7 Checking parallel running of solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.8 Adjusting parallel running of solar panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.9 Renewing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.10 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.11 Adjusting wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.12 Removing and installing solar panel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.13 Removing and installing sliding/tilting sunroof drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.14 Adjusting drive for sliding/tilting sunroof (zero position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.15 Removing and installing wind deflector drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.16 Removing and installing sliding/tilting sunroof automatic preselector . . . . . . . . . . . . . . . . 134
2.17 Removing and installing DC-DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.18 Removing solar contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.19 Removing and installing carrier unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.20 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.21 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.22 Adapting components of sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.23 Coding sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Contents iii
Phaeton 2003 ➤
1 Front bumper cover of vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1.1 Repairing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.3 Assembly overview - front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.4 Removing and installing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.5 Front bumper cover add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.6 Front bumper cover substructure parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.7 Installation notes for ACC sensor on right G259 / left -G 258- . . . . . . . . . . . . . . . . . . . . . . 148
1.8 Removing and installing adaptive cruise control sensor -ACC- . . . . . . . . . . . . . . . . . . . . . . 148
1.9 Removing and installing bumper cover insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.10 Assembling bumper cover insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2 Front bumper cover of vehicles from 06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.1 Repairing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.3 Assembly overview - front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.4 Removing and installing front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.5 Front bumper cover add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.6 Front bumper cover substructure parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3 Rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.1 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.3 Assembly overview - rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.4 Removing and installing rear bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.5 Rear bumper cover add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.6 Rear bumper cover substructure parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.7 Assembly overview - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1 Flush bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.3 Repairing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.4 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.5 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.6 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.7 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.8 Preparing windscreen with viewing window for chassis number for vehicles without chassis
number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.9 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.10 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.11 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.12 Preparing a removed windscreen for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.13 Preparing new window for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.14 Preparing body flange for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.15 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.16 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.17 Touching up paint damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.18 Cleaning off excess adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2 Front door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.2 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.3 Removing and installing electric window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.4 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.5 Removing and installing window slot seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.6 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
iv Contents
Phaeton 2003 ➤
3 Rear door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

3.1 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.2 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.3 Removing and installing electric window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.4 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.5 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.6 Removing and installing window slot seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.7 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

1 Removing and installing wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.1 Front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.2 Rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.2 Assembly overview - rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.5 Removing and installing side turn signal repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.6 Removing and installing entry light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.7 Removing and installing warning lamp for lane change assist . . . . . . . . . . . . . . . . . . . . . . 210
2.8 Assembly overview - rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.9 Removing and installing rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.10 Removing and installing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3 Radiator grille of vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4 Radiator grille of vehicles from 06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.3 Removing and installing VW emblem on vehicles without adaptive cruise control . . . . . . 219
4.4 Removing and installing VW emblem on vehicles with adaptive cruise control . . . . . . . . . . 222
5 Roof mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5.1 Assembly overview - roof strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5.2 Removing and installing securing clips for roof moulding . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.3 Assembly overview - drip channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.4 Assembly overview - water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6 Protective strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.1 Assembly overview - protective moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.2 Renewing protective side strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
6.3 Assembly overview - trim strips on wing and side panel . . . . . . . . . . . . . . . . . . . . . . . . . . 231
6.4 Renewing trim strip insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
6.5 Assembly overview - cover strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7 Sill trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
7.1 Assembly overview - sill protective strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
7.2 Assembly overview - sill panel mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.3 Renewing sill panel moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8 Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.2 Installation instructions for lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.3 Rear lettering - dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.4 Dimensions of Volkswagen R GmbH emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Contents v
Phaeton 2003 ➤
vi Contents
Phaeton 2003 ➤
50 – Body - front
1 Lock carrier
1.1 Tools
Special tools and workshop

equipment required
♦ Guide pins -T 10093-
♦ Torque wrench 5…50 Nm -
V.A.G 1331-
♦ Torque wrench 40…200
Nm -V.A.G 1332-
1.2 Fitting locations of adaptive cruise con‐

trol senders
1.2.1 ACC sender on right -G259- / ACC

sender on left -G258-
Note
The ACC sender on right -G259- is described; the description for

the ACC sender on left -G258- is to be derived from this.
1. Lock carrier 1
Phaeton 2003 ➤
Location: on back of cross member.

The ACC sender on right -G259- must be adjusted after:
• every removal and installation or renewal of the ACC sender
on right -G259-
• every removal and installation or renewal of the front bumper
carrier
• if there is reason to believe that a force has been exerted on
either of these parts, e.g. a head-on collision or similar.
Installation instructions ⇒ page 10 .
Removing and installing ACC sender on right -G259-
⇒ page 11
1.2.2 ACC sensor -G550-

Fitting location: in centre of lock carrier.
The ACC sensor -G550- must be adjusted after:
• every removal and installation or renewal of the ACC sensor
-G550-
• every removal and installation or renewal of the lock carrier,
1.3 Assembly overview - lock carrier, service position
2 Rep. gr.50 - Body - front

Phaeton 2003 ➤
1 - Bolt
❑ Qty. 4
❑ 50 Nm
❑ Installation instructions
⇒ page 10 .
2 - Bolt
❑ Qty. 4
❑ 20 Nm
⇒ page 10 .
3 - Bolt
❑ Qty. 4
❑ 20 Nm
4 - Bolt
❑ For air ducts of air filter.
❑ Qty. 4
5 - Lock carrier with add-on
parts
6 - Guide
7 - Bolt
❑ Qty. 5
❑ 8 Nm
8 - Sender for right ACC -
G259-
❑ Removing and installing
ACC sender on right -
G259- ⇒ page 11
⇒ page 10 .
1. Lock carrier 3
Phaeton 2003 ➤
1.4 Service position
1.4.1 Moving to service position
– Remove front bumper cover of vehicles up to 05.2010

⇒ page 143 , of vehicles from 06.2010 ⇒ page 153 and detach
side guide elements -6- from wing.
– Remove noise insulation of vehicles up to 05.2010
⇒ page 18 , of vehicles from 06.2010 ⇒ page 19 .
– Remove bolts -4- for air duct between lock carrier and air
cleaner on lock carrier.
– Remove seal on lock carrier.
– Unscrew bolt -2- and screw special guide pins -T 10093- tool
into right- and left-hand longitudinal member.
– Unscrew bolts -1- and -3- and pull the lock carrier -5- forwards
in area of special guide pins -T 10093- tool.

Phaeton 2003 ➤
– The lock carrier -1- can be pulled forwards about 10 cm on the

special guide pins -T 10093- tool.
1.4.2 Moving from service position
– Align lock carrier on longitudinal members and between wings

– Gap dimensions ⇒ Body Repairs; Rep. gr. 00 ; Technical data;
Body gap dimensions .
– Note installation instructions for bolt -1- and bolt -2-
⇒ page 10
1. Lock carrier 5
Phaeton 2003 ➤
– In vehicles with ACC, observe installation instructions for the

ACC sender on right -G259- ⇒ page 10 .
1.5 Assembly overview - lock carrier with attachments
1 - Lock carrier with add-on

parts
2 - Bolt
❑ Qty. 4
❑ 20 Nm
3 - Oil cooler
4 - Hexagon nut
❑ Qty. 4
❑ 8 Nm
5 - Bumper carrier
❑ Is pulled out with lock
carrier
6 - Bolt
❑ Qty. 5
❑ 8 Nm
7 - Guide
8 - Bolt
❑ Qty. 4
❑ 50 Nm
⇒ page 10 .
9 - Bolt
❑ Qty. 4
❑ 20 Nm
⇒ page 10 .
10 - Sender for right ACC -
G259-
⇒ page 10 .
1.6 Removing and installing lock carrier with

add-on parts
1.6.1 Removing
Note
♦ Because the lock carrier is a safety-relevant component, it

must not be repaired.
♦ If damaged, the lock carrier must be renewed.

Phaeton 2003 ➤

⇒ page 143 , of vehicles from 06.2010 ⇒ page 153 and detach
side guide elements from wing.
– Remove noise insulation of vehicles up to 05.2010
– Disconnect Bowden cable from coupling and disconnect elec‐
trical connections.
– Remove seal on lock carrier.
– Drain coolant and disconnect coolant hoses.
– Loosen refrigerant pipe. ⇒ Heating and air conditioning sys‐
tem; Rep. gr. 87 ; Air conditioning system; Removing and
installing condenser
– Unbolt oil cooler -3- at hexagonal nuts -4- beneath bumper
carrier and swing to side.
– Remove bolts -8- and -9-
– Unscrew bolts -2- and lift the lock carrier -1- out together with
bumper carrier -5- with a second mechanic.
1. Lock carrier 7
Phaeton 2003 ➤
WARNING
Do not start the engine if the air conditioning system and/or the
coolant system lines are disconnected.
Note
♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.
1.6.2 Installing
– Align lock carrier to longitudinal members and between wings

⇒ Body Repairs; Rep. gr. 00 ; Technical data; Body gap di‐
mensions .
– Note installation instructions for bolt -8- and bolt -9-
⇒ page 10
– In vehicles with ACC, observe installation instructions for the
ACC sender on right -G259- ⇒ page 10 .

Phaeton 2003 ➤
During assembly, ensure that all connectors and hose connec‐

tions are properly installed.
Install in reverse order of removal.
1.7 Assembly overview - lock carrier attaching parts
1 - Lock carrier
2 - Bolt
❑ Qty. 4
❑ 20 Nm
3 - Oil cooler
4 - Hexagon nut
❑ Qty. 4
❑ 8 Nm
5 - Bolt
❑ Qty. 6
❑ 8 Nm
6 - Retaining bracket
❑ Qty. 2
7 - Expanding nut
❑ Qty. 2
8 - Air guide
9 - Bolt
❑ Qty. 2
❑ 2 Nm
10 - Bolt
❑ Qty. 4
❑ 50 Nm
11 - Hexagon nut
❑ Qty. 2
❑ 8 Nm
12 - Bolt
❑ Qty. 4
❑ 20 Nm
13 - Bolt
❑ Qty. 2
❑ 1 Nm
1. Lock carrier 9
Phaeton 2003 ➤
1.8 Installation instructions for longitudinal

members
– Illustration shows a section of longitudinal member on right
side of vehicle. Bolt -1- ( -M 10- x 35), on longitudinal member
on outer side of vehicle, is tightened to 50 Nm. Bolt -2- ( -M 8-
x 40), on longitudinal member in centre of vehicle, is tightened
to 20 Nm.
1.9 Installation instructions for vehicles with

adaptive cruise control
1.9.1 Installation instructions for ACC sender

on right -G259- / ACC sender on left -
G258-
Note


Phaeton 2003 ➤

• every removal and installation or renewal of the ACC sender
on right -G259-
• every removal and installation or renewal of the front bumper
carrier
A distance of 10 mm for adjustment purposes must be maintained
between the back of the ACC sender on the right -G259- and the
radiator.
When installing the ACC sender on the right -G259- , ensure that
the sender does not touch the radiator located behind it.
When installing the front bumper cover, ensure that the front
bumper cover does not touch the ACC sender on the right -
G259- .
Ensure that the radar-compatible cover is installed in the front
bumper cover.
The ACC sender on the right -G259- is adjusted with the ACC
setting device -VAS 6041- and the wheel alignment unit .
The description can be found in the wheel alignment unit .
1.9.2 Installation instructions for the ACC sen‐

sor -G550-
The ACC sensor -G550- must be adjusted after:
• every removal and installation or renewal of the ACC sensor
-G550-
• every removal and installation or renewal of the lock carrier,
The ACC sensor -G550- is adjusted with the ACC setting device
-VAS 6041- and the wheel alignment unit .
1.10 Removing and installing ACC senders
1.10.1 Removing and installing ACC sender on

right -G259- / ACC sender on left -G258-
Note

In order to remove the ACC sender on the right -G259- , the front
bumper cover must first be removed - vehicles up to 05.2010
⇒ page 143 , vehicles from 06.2010 ⇒ page 153 .
1. Lock carrier 11
Phaeton 2003 ➤
The ACC sender on the right -G259- -3- is located behind the front
bumper carrier -1-.
– Remove the 4 bolts -4- and detach connector -2-.
– Always observe installation instructions ⇒ page 10 .
1.10.2 Removing and installing ACC sensor -

G550-
The ACC (adaptive cruise control) sensor -G550- -1- is fitted in
the lock carrier -4-.
Vehicles from 06.2010
– Remove radiator grille ⇒ page 217 .
Continued for all vehicles
– Unscrew bolts -3- and disconnect connector -2-.

Phaeton 2003 ➤
2 Wing
2.1 Tools
Special tools and workshop equipment required
♦ Torque wrench 2…10 Nm -V.A.G 1783-
2.2 Assembly overview - front wing
Note
Only the left side is shown. The right side is similar.
2. Wing 13
Phaeton 2003 ➤
1 - Wing
❑ Material: PUR RIM
2 - Bolt
❑ Observe tightening se‐
quence ⇒ page 17 .
❑ Qty. 15
❑ 6 Nm
3 - Foam underlay
❑ Self-adhesive.
4 - Anti-friction foil
❑ On web plate.
❑ On A-pillar.
❑ On sill.
7 - Spacer plate
❑ If necessary, use multi‐
ple spacer plates.
8 - Hexagon nut
❑ Observe tightening se‐
quence ⇒ page 17 .
❑ Qty. 7
❑ 6 Nm

Phaeton 2003 ➤
2.3 Removing and installing front wing
2.3.1 Removing

– Remove wheel housing liner ⇒ page 205 .
– Unscrew bolts -2 and 9- as well as nuts -8-.
– Remove wing.
2. Wing 15
Phaeton 2003 ➤
2.3.2 Installing
Before bolting on wing, apply a zinc intermediate layer -AKL 381

035 50- to bolted connection points in area where wheel housing
contacts A-pillar.
– Observe order in which bolts are tightened.
– Bolting sequence ⇒ page 17 .
Specified torque for bolts: 6 Nm.
– Ensure gaps are parallel and specified dimensions are main‐
tained. ⇒ Body Repairs; Rep. gr. 00 ; Technical data; Body
gap dimensions

Phaeton 2003 ➤
2.4 Front wing - bolting sequence
Note
♦ Only the left side is shown. The right side is similar.

♦ The specified bolting sequence must strictly be maintained.
– The sequence in which the nuts and bolts 1 - 23 are tightened

can be seen in the illustration.
– Bolt -1- is on the top edge of the wing at the A-pillar.
Specified torque for bolts: 6 Nm.
2. Wing 17
Phaeton 2003 ➤
3 Noise insulation
3.1 Tools
♦ Torque wrench -V.A.G 1783-
3.2 Assembly overview - noise insulation in vehicles up to 05.2010
1 - Front noise insulation

2 - Rear noise insulation
3 - Bolt
❑ Qty. 2 on each side.
❑ 2 Nm
4 - Retainer
5 - Bolt
❑ Joins front and rear
noise insulation
❑ Qty. 5.
❑ 4.5 Nm
6 - Bolt
❑ Connect front noise in‐
sulation to wheel hous‐
ing liner
❑ 2 Nm
7 - Bolt
sulation to lock carrier
❑ Qty. 3.
❑ 4.5 Nm

Phaeton 2003 ➤
3.3 Assembly overview - noise insulation in vehicles up to 06.2010
1 - Front noise insulation

2 - Rear noise insulation
3 - Bolt
❑ Joins front and rear
noise insulation
❑ Qty. 5.
❑ 3 Nm
4 - Bolt
❑ 6 Nm
5 - Bolt
❑ 2 Nm
6 - Nut
❑ 2 Nm
7 - Bolt
sulation to wheel hous‐
ing liner
❑ 2 Nm
8 - Bolt
sulation to lock carrier
❑ Qty. 3.
❑ 3 Nm
3. Noise insulation 19
Phaeton 2003 ➤
55 – Bonnet, rear lid

1 Contact corrosion!
The Phaeton's doors, bonnet and rear lid are made of aluminium.
When these parts are installed, special care must be taken re‐
garding contact corrosion.
Contact corrosion can occur if unsuitable fastening elements
(screws, bolts, nuts, washers) are used.
For this reason, only connecting elements with a special surface
coating (Dacromet) have been fitted. These elements can be rec‐
ognised by their green colour.
Furthermore, rubber, plastic parts and adhesives are made of
non-conducting materials.
If unsure about the reusability of a specific part, always fit a new
part.
WARNING
♦ Use genuine parts only.

♦ Accessories must be approved by VW AG!
♦ Damage due to contact corrosion is not covered by the
warranty.
20 Rep. gr.55 - Bonnet, rear lid

Phaeton 2003 ➤
2 Bonnet
2.1 Tools
♦ Removal lever -80 - 200-
2.2 Assembly overview - bonnet of vehicles up to 05.2010
2. Bonnet 21
Phaeton 2003 ➤
1 - Bonnet
❑ Move bonnet to service
position ⇒ page 24
❑ Removing:
– Remove pollen filter and
retaining frame.
– Remove cables/hoses
for windscreen washer
system and washer jets.
– Unclip hinged cover.
– Remove gas struts -5-

from bonnet.
⇒ page 24 .
– Undo bolts -6- and re‐

move bonnet with the
help of a second me‐
chanic.
❑ Adjusting ⇒ page 33
2 - Adjustment screw
3 - Stop buffer
4 - Hinge
5 - Gas strut
⇒ page 24
❑ Releasing gas
⇒ page 42
6 - Bolt
❑ 20 Nm
7 - Stop buffer
8 - Guide
9 - Insulation
❑ Removing and installing ⇒ page 25
10 - Adjustment buffer
❑ Can be screwed in and out to adjust the bonnet height in relation to the wings
11 - Stop buffer

Phaeton 2003 ➤
2.3 Assembly overview - bonnet of vehicles up to 06.2010
1 - Bonnet
❑ Move bonnet to service
position ⇒ page 24
❑ Removing:
– Remove pollen filter and
retaining frame.
– Remove cables/hoses
for windscreen washer
system and washer jets.
– Unclip hinged cover.

– Remove gas struts -5-
from bonnet.
⇒ page 24 .
– Undo bolts -6- and re‐

move bonnet.
2 - Adjustment screw
3 - Stop buffer
4 - Hinge
5 - Bolt
❑ 20 Nm
6 - Cover
7 - Gas strut
⇒ page 24
❑ Releasing gas
⇒ page 42
8 - Stop buffer
9 - Guide
10 - Insulation
❑ Can be screwed in and out to adjust the bonnet height in relation to the wings
12 - Stop buffer
2. Bonnet 23
Phaeton 2003 ➤
2.4 Removing gas strut

– Open bonnet.
– Position a small screwdriver beneath spring clip -2-.
– Raise spring clip -2- until it can be moved over ball socket in
direction of -arrow-.
– Pull gas strut -1- off ball-head pins -3- and -4-.
After removing gas strut -1-, slide spring clip -2- back immediately.
WARNING
Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.
– Releasing gas from gas strut -1- ⇒ page 42 .
2.5 Service position for bonnet

Remove gas strut ⇒ page 24 .
– Press bonnet into service position. In this position, insert a 6
mm punch or a 6 mm drill bit -1- through both hinge arms -2-.
The bonnet is supported.

Phaeton 2003 ➤
2.6 Removing and installing insulation of ve‐

hicles up to 05.2010
2.6.1 Removing
– Lever out clips -1- (Qty. 18) using removal lever -80 - 200- .
– Remove insulation -2-.
2.6.2 Installing
• The clips -1-must be fitted with the short side outwards in the
insulation -2-.
2.7 Removing and installing insulation of ve‐

hicles up to 06.2010
2.7.1 Removing
2. Bonnet 25
Phaeton 2003 ➤
– Lever out retaining clips -3 - (Qty. 12) using removal lever

-80-200- .
– Pull insulation -2- out of oblong holes in bonnet -1-.

Phaeton 2003 ➤
2.7.2 Installing
– Slide insulation -2- with fitting lugs into oblong holes of bonnet
-1-.
– Insert all retaining clips -3- into bonnet until they engage.
2. Bonnet 27
Phaeton 2003 ➤
3 Lock and release components of

bonnet
3.1 Assembly overview - bonnet lock and release components of vehicles up

to 05.2010
1 - Safety catch
❑ The safety catch is bol‐
ted onto the bonnet with
3 bolts
2 - Bowden cable
❑ Is divided into two by
Bowden cable coupling
-9-.
❑ The Bowden cable can
be disconnected at its
coupling in order to re‐
move the lock carrier.
❑ Disconnecting
⇒ page 35 .
3 - Release lever
⇒ page 35
4 - Lower A-pillar trim
5 - Bolt
❑ 6 Nm
6 - Mounting bracket
❑ Bowden cable attached.
7 - Securing clip
8 - Sealing grommet
9 - Bowden cable coupling
❑ Separating Bowden ca‐
ble ⇒ page 35
10 - Bonnet lock
⇒ page 29

Phaeton 2003 ➤
3.2 Assembly overview - bonnet lock and release components of vehicles up

to 06.2010
1 - Safety catch
❑ The safety catch is bol‐
ted onto the bonnet with
4 bolts
2 - Bowden cable
❑ It is divided in two by the
Bowden cable coupling
-9-.
❑ The Bowden cable can
be disconnected at its
coupling in order to re‐
move the lock carrier.
❑ Disconnecting
⇒ page 35 .
3 - Release lever
⇒ page 35
4 - Lower A-pillar trim
5 - Bolt
❑ 6 Nm
6 - Mounting bracket
❑ Bowden cable attached.
7 - Securing clip
8 - Sealing grommet
9 - Bowden cable coupling
❑ Separating Bowden ca‐
ble ⇒ page 35
10 - Bonnet lock
⇒ page 29
3.3 Removing and installing bonnet lock
3.3.1 Removing
Vehicles from 06.2010
– Remove radiator grille ⇒ page 217 .
3. Lock and release components of bonnet 29

Phaeton 2003 ➤
Vehicles with cover for lock securing bolts

– To unclip cover for lock securing bolts, press locking lugs -2-
together.
– Now cover -1- can be levered off forwards.
– Remove left and right air ducts -1-.
– Pull Bowden cable coupling -1- from lock carrier and separate
Bowden cable ⇒ page 35 .

Phaeton 2003 ➤
– Now detach the connector -1- for the contact switch for bonnet
-F266- .
Connector is located on right (in direction of travel) of lock carrier.
– Remove the 3 bolts -1- from lock carrier and remove bonnet
lock -2- upwards to left.

Phaeton 2003 ➤
– Unclip contact switch 1 -F266- -1- for bonnet from bonnet lock.
When doing this, note lug -arrow A-.
– To unclip Bowden cable -3-, press tab -2- and Bowden cable
together.
– The fastening is released and you can remove the Bowden
cable from the bonnet lock.
3.3.2 Installing
Installation is carried out in reverse order.

Phaeton 2003 ➤
3.4 Adjusting bonnet and bonnet lock
To carry out initial adjustment of the bonnet, the vehicle must be

standing on the ground and the latch hook must be removed.
– Align bonnet -1- between wings by moving the position of the
bonnet hinges.
– Front part of bonnet can be adjusted to height of the wings
using adjustment buffers -10-.
– Height of rear of bonnet in relation to wings can be adjusted
with the adjuster bolt -2-.
The size of the gap to the wings is 3 mm ⇒ Body Repairs; Rep.
gr. 00 ; Technical data; Body gap dimensions .
– After adjusting bonnet, reinstall safety catch.
If gaps change when the bonnet is closed, correct the adjustment
via bonnet lock.
Adjust bonnet lock as described below.

Phaeton 2003 ➤
Vehicles with cover for lock securing bolts

– To unclip cover for lock securing bolts, press locking lugs -2-
together.
– Now cover can be levered off forwards.
– Remove radiator grille in the case of vehicles up to 05.2010
⇒ page 214 , in the case of vehicles from 06.2010
⇒ page 217 .

Phaeton 2003 ➤
In order to show this area of the bonnet more clearly, the bonnet
is shown in the released position.
– Now loosen 3 securing bolts -1- to correct or adjust bonnet
gaps.
3.5 Detaching Bowden cable

– Pull Bowden cable coupling off lock carrier.
– Open Bowden cable coupling by releasing locking tabs with a
small screwdriver -arrows-.
– Take front Bowden cable -1- out of coupling-2-.
Note
When installing, ensure that the Bowden cable sleeve is inserted

correctly and the coupling engages.
3.6 Removing and installing release lever
3.6.1 Removing

Phaeton 2003 ➤
– Pull release lever -5- approx. 2 cm.

– Insert a small screwdriver in the gap between the release lever
-5- and clip -6-.
– Release release lever again and unclip clip from release lever
(clip will fall behind trim).
– Remove bolt -4-.
– Unclip trim -3- in centre at right angles out from bearing bracket
-1- of A-pillar.
– Then unclip trim -3- from sill with lower clips -7-.

Phaeton 2003 ➤
3.6.2 Installing
– First clip trim -3- at bottom into sill. Then press in upper clip.
– Secure trim with bolt -4-.
– Now the clip -6- is engaged completely in the release lever.
– Then press release lever onto mounting in bearing bracket.

Phaeton 2003 ➤
4 Rear lid
4.1 Tools

equipment required
♦ Door alignment tool -3320-
♦ Bit -T 10153 XZN 8-
♦ Bit -T 10154 XZN 10-

Phaeton 2003 ➤
4.2 Assembly overview - aluminium hinge and hydraulic unit
Note
The hydraulic unit consists of the hydraulic pump, the lines and the hydraulic cylinders. In the event of a mal‐
function, the complete hydraulic unit must be renewed.
1 - Lid
❑ Gap dimensions ⇒ Body
Repairs; Rep. gr. 00 ;
Technical data; Body
gap dimensions .
2 - Noise insulation
❑ Halves are bonded to‐
gether.
3 - Hydraulic pump
❑ Installed in side panel.
❑ Part of hydraulic unit.
4 - Bolt
❑ 22 Nm
⇒ page 42
6 - Hydraulic cylinder
❑ Part of hydraulic unit.
7 - Hexagon nut
❑ 12 Nm
8 - Threaded plate
9 - Side panel
10 - Hinge
11 - Gas strut
12 - Bolt
❑ 22 Nm
13 - Cover
14 - Bolt
❑ 22 Nm
15 - Bolt
❑ 22 Nm
16 - Cover
17 - Bolt
❑ 22 Nm
4. Rear lid 39
Phaeton 2003 ➤
4.3 Removing and installing hydraulic unit
4.3.1 Removing
Note
The hydraulic unit consists of the hydraulic pump, the lines and the hydraulic cylinders. In the event of a mal‐
function, the complete hydraulic unit must be renewed.
– Remove luggage compartment side panel trim ⇒ General

body repairs, interior; Rep. gr. 70 ; Trims, insulation; Luggage
and load compartment trims .
– Removing rear shelf lower part ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Trims, insulation; Rear shelf .
– Release hydraulic cylinders on both sides.
– Push securing clip -5- to side in direction of hydraulic cylinder.
Take hydraulic cylinder off front ball-head pin.
– Hydraulic cylinder -1- only has to be levered from rear ball-
head pin -7- (not fitted with retaining clip).

Phaeton 2003 ➤
– Hydraulic lines -2- are secured with 7 clips -3-.

– Pull hydraulic pump -4- with noise insulation out of side panel.
4.3.2 Installing
4.4 Assembly overview - steel hinge
1 - Lid
❑ Gap dimensions ⇒ Body
Repairs; Rep. gr. 00 ;
Technical data; Body
gap dimensions .
2 - Handle trim
3 - Trim
⇒ General body repairs,
interior; Rep. gr. 70 ;
Removing and installing
rear lid trim
4 - Hinge
5 - Bolt
❑ 22 Nm
6 - Hexagon nut
❑ 12 Nm
7 - Threaded plate
8 - Gas strut
⇒ page 42
9 - Bolt
❑ 22 Nm
❑ Releasing gas
⇒ page 42
10 - Cable duct
❑ Unbolt from rear lid and
separate connectors.
❑ The part called "adjustment buffer" in other vehicles is not for adjusting the rear lid. They have the function
of stabilising and damping the rear lid. The adjusting buffer is referred to as damper below.
❑ Before removing, remove trim.
❑ Removing
❑ Turn adjustment buffer by 90 degrees using a ring spanner (24 mm) and take out of shaped hole.
4. Rear lid 41
Phaeton 2003 ➤
4.5 Removing gas strut

– Support rear lid.
– Position a small screwdriver beneath spring clip -2-.
– Raise spring clip -2- until it can be moved over ball socket in
direction of -arrow-.
– Pull gas strut -1- off ball-head pins -3- and -4-.
After removing gas strut -1-, slide spring clip -2- back immediately.
WARNING
Proceed with care if gas strut is reused. Spring clip must not
be levered completely out of ball socket, as it will otherwise be
damaged. Gas strut will spring out of mounting, causing dam‐
age or injury to operator.
– Releasing gas from gas strut -1- ⇒ page 42
4.6 Releasing gas from gas strut

– Clamp gas strut in vice in area x = 50 mm.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
– Saw through cylinder of gas strut within first third of cylinder's

overall length using piston rod end of cylinder as reference
point.
Note
♦ Wear eye protection when sawing.

♦ Cover area of saw cut with a cloth.
♦ Dispose of oil and cloth via existing disposal channels.
4.7 Adjusting rear lid

The rear lid can be adjusted only via the striker pin on lock cross
member. The rear lid lock is bolted directly to the rear lid. It does
not have elongated holes, so it cannot be adjusted.
The part called "adjustment buffer" in other vehicles is not for ad‐
justing the rear lid. They have the function of stabilising and
damping the rear lid. The adjusting buffer is referred to as damper
below.
The rear lid adjustment is described step by step below. This in‐
cludes basic adjustment of the lid, the striker plates and the
damper.
4.8 Basic adjustment of rear lid

To carry out basic adjustment of rear lid, remove lock carrier cover
⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage
compartment trim; Removing and installing lock carrier cover .

Phaeton 2003 ➤
– Loosen grub screw -1- until it is visible in rubber buffer. Now

pull detent slide -2- out of damper.
– Remove bolts -1- and remove striker plate.
– Lift up locking clip -1- using screwdriver and pull gas strut off
ball-head pins -3-.
Note
If the gas strut is to be re-used, do not prise retaining clips -1-

completely out of the ball socket, otherwise they will be damaged.
4. Rear lid 43
Phaeton 2003 ➤
– Hinge can be moved in oversized holes by loosening bolts

-1- with door alignment tool -3320- and bit -T 10153 XZN 8-
and bit -T 10154 XZN 10- on lid hinge and hexagon nut -2-
through luggage compartment.
Note
♦ The rear lid is adjusted correctly if the gaps/shut lines are even
all around, the lid is not too deep or too high and all contours
align when the lid is closed.
♦ Vehicle must be standing on its wheels when adjustments are
performed.
– Following adjustment, bolts -1- and hexagon nut -2- must be

tightened to proper torque setting.
Bolt -1- 20 Nm
Hexagonal nuts -2- 12 Nm
– For vehicles with hydraulic boot opener, the hydraulic unit, hy‐
draulic cylinder and relay lever must be removed.
– Now striker plate can be reinstalled, but bolts should not yet
be tightened.
4.9 Adjusting striker plate with lock cover re‐

moved
– Move striker plate to upper position -arrow- and tighten bolts
-1-.
– Close rear lid and check the adjustment.
– By loosening bolts -1-, striker plate can be moved in oversized
holes.
Note
performed.
– Following adjustment, retighten bolts -1- to specified torque

setting.
Bolt -1- 20 Nm
4.10 Adjusting striker plate with lock cover in‐

stalled
Note
performed.

Phaeton 2003 ➤
– Press covers -2- down. Using special tool 3320/3, you can
loosen striker plate bolts -1- and move it in oversized holes.
– Close rear lid and check the adjustment.
For vehicles with servo opener, you can close or open rear lid
either via contact switch in rear lid or remote control key.
– Following adjustment, retighten bolts -1- to specified torque
setting.
Bolt -1- 20 Nm
4.11 Adjusting dampers

Up to this point, damper and lock cover have been removed.
– Install lock cover.
– Insert notched slide in damper.
– Close rear lid with light pressure at centre of lid.
– Open rear lid again.
– Screw in clamping screw -1- to dimension a = 25 mm.
4. Rear lid 45
Phaeton 2003 ➤
5 Lock parts with servo rear lid opener
5.1 Assembly overview - lock parts with servo rear lid opener
1 - Lock cylinder carrier

❑ The lock cylinder can
only be removed in con‐
junction with the carrier.
⇒ page 47
2 - Relay lever
3 - Retaining plate
4 - Bolt
❑ 4 Nm
5 - Bolt
❑ These bolts must al‐
ways be tightened first.
❑ 4 Nm
6 - Rear lid lock
❑ Removing:
❑ Remove rear lid trim ⇒
General body repairs,
rear lid trim .
❑ Detach connector from
lock.
❑ Remove bolts -8- and
-7- and remove lid lock
-6-.
❑ Installing:
Note
Bolts -7- must always be tightened

first.
❑ Installation is carried out
in reverse order.
7 - Bolt
❑ Qty. 2
❑ 20 Nm
❑ These bolts must always be tightened first.
8 - Bolt
❑ 20 Nm
9 - Lock plate
❑ Adjusting - within oversized holes.
❑ Gap dimensions ⇒ Body Repairs; Rep. gr. 00 ; Technical data; Body gap dimensions .
10 - Bolt
❑ 20 Nm

Phaeton 2003 ➤
11 - Central locking control motor

12 - Power latching positioning motor
5.2 Removing and installing lock cylinder

carrier
5.2.1 Removing
– Remove rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing rear lid trim .
– Separate connectors -3-.
– Remove securing bolts -2- for retaining clip.
– Now loosen bolts -1- until retaining clip can be removed from
lock cylinder carrier over key holes in direction of arrow.
– Now lock cylinder carrier can be removed from outside.
5.2.2 Installing
– Insert lock cylinder carrier into lid.
– Now join retaining clip to carrier and lightly tighten bolts -1-
against retaining clip.
– After starting bolts -2- and lightly tightening them against lid,
lock cylinder carrier can be centred from outside by pushing it
within aperture in lid.
Note
When installing lock cylinder carrier, bolts -1- must be tightened

first.
5. Lock parts with servo rear lid opener 47

Phaeton 2003 ➤
5.3 Removing and installing lid lock
5.3.1 Removing
– Disconnect connection -1- and remove bolts 2 and -3-.
– Remove rear lid lock.
5.3.2 Installing
Note
When installing lid lock, bolts -3- must be tightened first.

Phaeton 2003 ➤
6 Lock parts with basic rear lid opener
6.1 Assembly overview - lock parts with basic rear lid opener
1 - Lock cylinder carrier

❑ The lock cylinder can
only be removed in con‐
junction with the carrier.
⇒ page 50
2 - Relay lever
❑ With coupling rod from
lock cylinder to lid lock.
3 - Retaining plate
4 - Bolt
❑ 4 Nm
5 - Bolt
❑ These bolts must al‐
ways be tightened first.
❑ 4 Nm
6 - Bolt
❑ 20 Nm
7 - Lid lock
❑ Removing:
❑ Remove rear lid trim ⇒
General body repairs,
rear lid trim .
❑ Detach connector from
lock.
❑ Remove bolts -8- and
-6- and remove lid lock
-7-.
❑ Installing:
Note
Bolts -8- must always be tightened

first.
❑ Installation is carried out in reverse order.
8 - Bolt
❑ 20 Nm
❑ These bolts must always be tightened first.
9 - Rear lid release motor (V 139)
10 - Bolt
❑ 20 Nm
11 - Lock plate
❑ Adjusting - within oversized holes.
6. Lock parts with basic rear lid opener 49

Phaeton 2003 ➤
❑ Gap dimensions ⇒ Body Repairs; Rep. gr. 00 ; Technical data; Body gap dimensions .
12 - Rear lid release motor (V254)

carrier
6.2.1 Removing
– Detach connectors -4- and-5-.
– Remove securing bolts -3- for retaining clip.
– Now loosen bolts -2- until retaining clip can be removed from
lock cylinder carrier over key holes in direction of arrow.
– Release securing element -1- and separate coupling rod.
– Now lock cylinder carrier can be removed from outside.
6.2.2 Installing
– Insert lock cylinder carrier into lid.
– Now join retaining clip to carrier and lightly tighten bolts -2-
against retaining clip.
– After starting bolts -3- and lightly tightening them against lid,
lock cylinder carrier can be centred from outside by pushing it
within aperture in lid.
Note
When installing lock cylinder carrier, bolts -2- must be tightened

first.
– Join both parts of coupling rod together on securing element

-1-. When doing this, ensure that bottom part of coupling rod
is at lowest point on relay lever of lid lock.
– Carefully lock securing element.

Phaeton 2003 ➤
6.3 Removing and installing lid lock
6.3.1 Removing
– Disconnect connections -1- and unbolt bolts 2 and -3-.
– Release securing element and separate coupling rod.
– Remove rear lid lock.
6.3.2 Installing
– Insert lid lock.
Note
When installing lid lock, bolts -3- must be tightened first.
– Join both parts of coupling rod together on securing element.

When doing this, ensure that bottom part of coupling rod is at
lowest point on relay lever of lid lock.
– Carefully lock securing element.
6. Lock parts with basic rear lid opener 51

Phaeton 2003 ➤
7 Tank flap unit
7.1 Tools
♦ Socket -T 10010-
7.2 Removing and installing tank flap unit
1 - Tank flap unit

❑ Removing:
❑ Unscrew tank cap.
❑ Press back the lock re‐
lease rod by by means
of the remote unlock
function.
❑ Remove cross-head
bolt -2-.
❑ Pull rubber part off fuel
tank filler neck and
swing tank flap unit out
of side panel.
❑ Installing:
❑ Assembly part and posi‐
tioning element have
been installed
❑ Install tank flap unit (rub‐
ber part rolled up) with
hinge side leading.
❑ Secure tank flap unit
and assembly part.
2 - Bolt
3 - Overflow hose
4 - Assembly part
❑ Pushed into side panel
❑ Bowden cable must be
clipped into assembly
part prior to assembly.
5 - Bowden cable
❑ Clipped into assembly
part and positioning ele‐
ment.

Phaeton 2003 ➤
6 - Seal
7 - Tank flap cup
❑ Removing and installing (can only be removed as part of tank flap unit)
❑ Press out securing pin in tank flap unit to remove the tank flap
8 - Positioning element bracket
9 - Fuel filler flap positioner
❑ Loosen with special tool hexagon socket screwdriver -T 10010- .
7. Tank flap unit 53

Phaeton 2003 ➤
57 – Front doors, door components, central locking

On the Phaeton, the doors, the rear lid and the bonnet are made
of aluminium. When these parts are installed, special care must
be taken regarding contact corrosion.
part.
WARNING

warranty.
54 Rep. gr.57 - Front doors, door components, central locking

Phaeton 2003 ➤
2 Front door
2.1 Tools

equipment required
♦ Socket -T 10072-
♦ Assembly tool -T 10118-
♦ Bit insert -3320/2-
♦ Roller -3356-
♦ Torque wrench -5…50 Nm
V.A.G 1331-
2. Front door 55
Phaeton 2003 ➤
2.2 Assembly overview - front door
Note
♦ Spacer plates are located behind the upper door hinge and the door. The spacer plates have varying thick‐
nesses. Consequently, the door hinge must be loosened only on rare occasions.
♦ The hinge bolts must always be renewed if loosened.
1 - Door
⇒ page 58
2 - Multi-point socket head bolt
❑ M8×28
❑ 20 Nm + 1/4 turn further
(90°).
❑ Always renew bolts after
loosening.
❑ Remove only this bolt
from hinge to remove
door.
❑ M8×28
(90°).
loosening.
4 - Door hinge with arrester
❑ Hinge is split.
❑ M8×28
❑ Installed from inside ve‐
hicle.
❑ Removing A-pillar lower
trim ⇒ General body re‐
pairs, interior; Rep. gr.
70 ; Pillar and side panel
trim
(90°).
loosening.
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
❑ Always renew bolts after loosening.
7 - Hexagon nut
❑ 23 Nm
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).

Phaeton 2003 ➤
9 - Door hinge
❑ Hinge is split.
❑ M8×22
❑ Installed from inside vehicle.
❑ To loosen or tighten the bolt, remove and install dash panel⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel
❑ 20 Nm + 1/4 turn further (90°).
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
12 - Door hinge
❑ Hinge is split.
13 - Spacer plate
❑ With material thicknesses of 0.5 mm, 1.0 mm and 1.5 mm.
2. Front door 57
Phaeton 2003 ➤
2.3 Removing and installing door
2.3.1 Removing
– Remove A-pillar lower trim ⇒ General body repairs, interior;

Rep. gr. 70 ; Pillar and side panel trim; Removing A-pillar lower
trim
– Pull bellows -2- off A-pillar. Guide electrical cables -4- out of
pillar through hole -arrow-.
– Remove hexagon nut -1- from upper and lower hinges.
Specified torque: 14 Nm.
– Remove lower bolt -3- from hinge.
Specified torque: 20 Nm + 1/4 turn further (90°)
Note
Always renew this bolt.

Phaeton 2003 ➤
– Lift door upwards out of hinge brackets.
2.3.2 Installing
2.4 Adjusting door

To achieve correct door adjustment, spacer plates of various
thicknesses can be placed under the upper door hinge. Other
measures such as raising the door have no effect. Subsequent
pressure from above will cause the door to sack again ⇒ General
body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel .
Note
♦ Spacer plates -3- of various thicknesses are installed between

the upper door hinge -2- and the door.
♦ Before adjusting gap by moving upper door hinge, gap can be
altered by inserting a different spacer.
♦ To enable adjustment of the front door, vehicle must be stand‐
ing on its wheels.
♦ The front door is adjusted correctly if the gaps/shut lines are
even all around, the door is not too deep or does not stand
proud and all contours align when the is door closed.
♦ To adjust or check the gap dimensions ⇒ Body Repairs; Rep.
♦ After reinstalling or adjusting, carry out corrosion protection
measures to hinges and bolts.
Location of spacer plates -3- is shown in figure.

Door hinge bolts -1- must always be renewed.
Only if this adjustment is not sufficient should you move door
hinge on A-pillar.
2.5 Adjusting striker pin
Note

ing on its wheels.
♦ Only the adjustment for the right front door is described. The
adjustment of the left front door is similar.
♦ The front door must lock fully when closing without any addi‐
tional force being required and must not have any play.
♦ The front door must not be pushed up or down as a result of
the striker pin adjustment.
2. Front door 59
Phaeton 2003 ➤
The following can be adjusted at the striker pin:

• When the front door does not align with the rear door.
– Release the striker pin -1- by loosening bolts -2- at the B-pillar.
– Adjust the front door with the striker pin -1- so that the front
door is flush with the rear door when shut (to prevent wind
noise).
– Tighten bolts -2- of striker pin -1-.
Specified torque for bolts -2-: 20 Nm.
2.6 Assembly overview - door handle and door lock
1 - Door lock
❑ The door lock can be re‐
moved only together
with the assembly carri‐
er.
⇒ page 65
2 - Bolt
❑ 20 Nm
3 - Retaining screw
❑ This bolt provides addi‐
tional security for the
lock cylinder housing.
❑ Only on vehicles with
lock cylinder.
❑ Socket -T 10072-
❑ Undoing this screw re‐
lease the catch for lock
cylinder housing -6-,
which can then be with‐
drawn from the bearing
bracket -12-.
❑ Screw -4- must not be
screwed in without the
lock cylinder housing
being inserted.
5 - Base
6 - Lock cylinder housing
❑ Removing ⇒ page 61
❑ Lock cylinder is not sup‐
plied as individual parts.
❑ Lock cylinder only on
driver side.
7 - Key
❑ Changing battery ⇒ page 75 .
❑ Adapting new or additional key to remote control ⇒ page 75 .

Phaeton 2003 ➤
8 - Door handle
❑ Door handle with (Keyless Entry) cable routing ⇒ page 65 .
9 - Base
10 - Cable (Keyless Entry)
❑ Exterior door handle with driver side cable routing ⇒ page 65 .
❑ Exterior door handle with front passenger side cable routing ⇒ page 65 .
11 - Bolt
❑ 6 Nm
12 - Bearing bracket
❑ Removing:
Door handle, lock cylinder housing and door assembly carrier have been removed.
❑ Remove bolt -11-, push back bearing bracket slightly and take it out of door.
13 - Cover
❑ Not supplied with door lock.
14 - Bowden cable
❑ Lock release
❑ Bolted and riveted to door lock.
❑ Not supplied with door lock.

housing
2.7.1 Removing
– Lever off cap -1-.
2. Front door 61
Phaeton 2003 ➤
– Pull door handle -1- and hold it. Unscrew bolt -3- onto stop
using socket insert -T 10072- . Lock cylinder housing -2- is now
released.
– Now loosen bolt -1- until lock cylinder housing -2- can be pulled
out of door handle bearing bracket at right angles.
2.7.2 Installing
– Insert lock cylinder housing at right angle into door handle
bearing bracket.
– Turn screw into bearing bracket with socket wrench.
The door handle engages in the lock cylinder housing with an
audible click.
– The lock cylinder housing must then be secured with bolt -1-;
see top part of illustration.
Note
During assembly, the door handle and lock cylinder housing

should be pressed against the door panel.
– Then perform remaining installation in reverse order of remov‐

al.

Phaeton 2003 ➤
• It is essential to check function, as door cannot be opened if

adjustment is not correct and Bowden cable is not properly
clipped.
2.8 Removing and installing door handle
2.8.1 Removing
Removing and installing lock cylinder housing ⇒ page 61 .
– Door handle with (Keyless Entry) cable routing ⇒ page 65 .
– Unclip clip -1- from door handle -2-.
– Swing door handle out of door.
2.8.2 Installing
2. Front door 63
Phaeton 2003 ➤
– Guide assembly tool -T 10118- through the opening on the

inside of the door panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool in spring -arrow A-.
– Hook spring into door lock by pulling assembly tool
-arrow B-.
The release lever is now secured.

Phaeton 2003 ➤
– Swing door handle into door.

– Pull clip -1- into opening in panel and engage it in door handle
-2-.
Note
Press door handle -2- against door panel when assembling.
– Pulling door handle unlocks the release lever.

Install lock cylinder housing ⇒ page 61 .
• Afterwards, the function must be checked, as an incorrectly
fitted and adjusted Bowden cable cannot open the door.
2.9 Door handle with (Keyless Entry) cable routing
1 - Window frame
❑ Remove window frame
⇒ General body repairs,
Trims, insulation; Re‐
moving and installing
door linings .
2 - Wiring harness
❑ Secured in upper door
area with cable tie.
❑ Removing assembly
carrier -4- ⇒ page 65 .
3 - Connector (Keyless Entry)
4 - Assembly carrier
2.10 Removing and installing door lock

Window regulator, door lock and loudspeaker are secured to the
assembly carrier.
2. Front door 65
Phaeton 2003 ➤
The door lock can be removed only together with the assembly
carrier.
Assembly carrier can only be removed when door window is un‐
bolted at window regulator clamping bolts. To do this, lower door
window to the height of the assembly holes in assembly carrier
and loosen clamping bolts.
2.10.1 Removing
– Remove front door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Trims, insulation; Removing and
installing door trim .
– Removing lock cylinder housing ⇒ page 61
– Unclip clip -1- from door handle.
– Lever out cover caps -1-.

– Lower door window until clamping bolts are accessible.
Note
If the work step cannot be carried out because there is a fault with
the electric window motor, remove motor to slide window down.
– Loosen bolts -2-.

– Push window upward and secure in position (e.g. with adhe‐
sive tape).
– Disconnect all connections -arrows-.

Phaeton 2003 ➤

– Unscrew bolts -2- Specified torque: 20 Nm.
– Unscrew bolts -arrows-. Pull assembly carrier at top off door,

raise and lift out of door to hinge side of door.
– Turn assembly carrier and pull connector off door lock.
– Then unclip the clips for electrical cables on back of assembly
carrier.
– Drive out clips -1- using a drift.

– Disconnect connections -3- and press rubber grommet -2- out
of the door assembly carrier.
– Lever door lock with retaining bracket off mounting plate using
a screwdriver.
Note
The retaining bracket is not part of the items supplied with the
door lock. Secured to door lock with a bolt and a pop rivet.
– Unclip Bowden cable -1- from door lock.

– Rotate the nipple of the Bowden cable through 90° and remove
it from the eye.
2.10.2 Installing
2. Front door 67
Phaeton 2003 ➤
Install door lock in reverse order.

– Pull release lever -1- in -direction of arrow-.
– Tension spring -2-, which is secured on door lock, in
-direction of arrow- with a screwdriver and hook locking lever
into spring.
Note
Hooking the operating lever in locks the lock. This prevents „incorrect“ attachment of the Bowden cable later.
– Insert assembly carrier in door.

Phaeton 2003 ➤
– Remove loudspeaker -1- before starting bolts for mounting

plate.
– Check that cable bracket -1- is correctly seated on impact bar

-2-.
Note
If cable bracket is not properly clipped to assembly carrier, wiring

harness may be damaged, resulting in failure of all electrical com‐
ponents in door.
– Insert all bolts. Tighten bolts -1- and -2- in the order specified
to specified torque 8 Nm.
– The remaining bolts can be tightened in any sequence.
– Press door window -3- into window channel -arrow- and tight‐
en clamping bolts -4- (Qty. 2) (10 Nm).
al.
• Test function before installing door trim.
2.11 Assembly overview - door power latching motor (V 278)
2. Front door 69
Phaeton 2003 ➤
1 - Door
3 - Door power latching motor
(V 278)
4 - Bolt
❑ Qty. 4
❑ 3.5 Nm
5 - Connector
6 - Bowden cable
2.12 Door seals

During production, a sealant is applied to the door seals, which
are then placed on the door flange and rolled on.
Note
♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, a tight seal is not guaranteed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called „tap-on“ seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

Phaeton 2003 ➤
2.13 Removing and installing door inner seal
2.13.1 Removing
– Remove the pillar trims as required ⇒ General body repairs,
interior; Rep. gr. 70 ; Pillar trim
– Remove sill panel mouldings ⇒ General body repairs, interior;
Rep. gr. 68 ; Interior equipment; Sill panel mouldings .
– Remove interior door seal from body flange.
2.13.2 Installing
– When installing door inner seal, start at upper radius of the
door aperture.
2.14 Removing and installing door outer seal
Note
♦ The description of removal and installation is only for the right

door outer seal. The removal and installation of the left door
outer seal is similar.
♦ Remove protective backing immediately before installation.
Working temperature about 20 °C.
♦ Use only adhesive remover D 002 000 10.
♦ The door outer seal must be bonded in place immediately after
cleaning.
2.14.1 Removing
– To remove door outer seal, door trim, both carrier frames and
window frame trim must be removed ⇒ General body repairs,
interior; Rep. gr. 70 ; Trims, insulation; Removing and instal‐
ling door trim .
– Pull door outer seal off door flange.
2. Front door 71
Phaeton 2003 ➤
2.14.2 Installing
– Remove existing adhesive residues with erasure disc of ad‐
hesive strip remover -VAS 6349- .
– Immediately before bonding door outer seal, clean bonding
surface thoroughly with adhesive remover D 002 000 10.
• Bonding surfaces must be free of dust and grease and there
should be no adhesive residues.
– To apply door outer seal, align coloured mark of seal with se‐
curing bolt -1- of window slot seal.
– Pull protective sheeting off in stages, then apply seal to door
flange and bond. Do not pull door outer seal to avoid stretching
seal.

Phaeton 2003 ➤
– Press complete bonding surface of seal -3- on door -1- all

around using roller -3356- .
– To do this, push the seal aside -arrow a- so that the roller
-3356- runs directly over the contact surface of the seal.
The roller can apply the necessary force -arrow b- to the bonding
surface -2- only when procedure described above is followed.
– If the seal has stretched, cut seal to required length and press
on butt joint well.
– If seal -3- comes loose in small areas again, press seal on well
again using roller -3356- .
Note
The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
again.
2.15 Door insulation
Note
♦ The insulation elements have the task of minimising noise and ensuring good sealing qualities. For this
reason, it is important to ensure that only serviceable insulation elements are installed and in the correct
position.
♦ The bonded insulation elements should always be renewed.
♦ Inserted damping parts are to be checked for damage, e.g. cracks, and renewed if necessary.
2. Front door 73
Phaeton 2003 ➤
1 - Door
2 - Sealing strip
❑ Bonded to A-pillar.
❑ Self-adhesive.
3 - Insulation
⇒ page 74
4 - Sound suppression
❑ Self-adhesive.
5 - Insulation
❑ Inserted in upper area of
B-pillar.
2.16 Removing and installing insulation

– The insulation elements -1- are attached to the outer support
panel -2-.

Phaeton 2003 ➤
2.17 Adapting ignition keys to remote control

Ignition keys with remote control can be adapted using the vehicle
diagnosis, testing and information system -VAS 5051- .
– Select „guided fault finding“ in diagnostic tester -VAS 5051- .
– Using the „GoTo“ key, select "Function/component selection"
and the following menu items one after the other:
♦ Body
♦ General body repairs
♦ 01 - Systems capable of self-diagnosis
♦ Convenience system
♦ Functions - convenience system
♦ Adapting keys to immobiliser
Note
The keys are automatically adapted to the radio remote control

system when they are adapted to the immobiliser.
2.18 Removing and installing batteries for

folding main key with remote control
system
1- Transmitter unit - upper part
2- Main key with programmable code transponder
3- Transmitter unit - lower part
4- Button battery
2.18.1 Removing
– Insert a screwdriver in the slot between the transmitter unit
-1- and the main key -2-.
– Move the screwdriver in direction of arrow and unclip the
transmitter unit from the main key.
2. Front door 75
Phaeton 2003 ➤
– Push transmitter unit apart in direction of arrow.
– Unclip batteries from retainers in direction of arrow using a

screwdriver.
2.18.2 Installing
Observe polarity and correct position when installing the batter‐
ies.
– Place the battery with the positive terminal downwards in the
transmitter unit (positive terminal is marked on housing).
– Engage battery in transmitter unit by pressing down lightly.
– Fit cover to transmitter unit (do not damage seal).
– Then engage the transmitter unit with the main key.
2.19 Assembly overview - batteries for main key (foldable) with remote control,
vehicles from 01.2004

Phaeton 2003 ➤
1 - Key with radio capsule

❑ Adaptation with radio re‐
mote control
⇒ page 75 .
❑ Individual radio capsu‐
les cannot be replaced
2 - LED
❑ When remote control is
operated, this LED must
flash briefly.
❑ If LED does not flash
during remote control
operation, the battery is
dead and must be re‐
newed.
3 - Battery
❑ Removing battery
⇒ page 77
❑ Installing battery
⇒ page 78

system, vehicles from 01.2004
2.20.1 Removing
– Insert a small screwdriver in the gap between cap -1- and key
-2-.
– Push the screwdriver in -direction of arrow- and prise cap off
key.
2. Front door 77
Phaeton 2003 ➤
– Push battery -1- in -direction of arrow- and withdraw it from key

-2- upwards -arrow b-.
2.20.2 Installing
Note polarity and correct position when installing battery.
– Insert battery -1- in key -2- in -direction of arrow- with the pos‐
itive pole underneath.
– Press lightly on the battery to engage it in the key.
– Now fit the cover to the key.
2.21 Assembly overview - batteries for main key (foldable) with remote control,
vehicles from 06.2010

Phaeton 2003 ➤
1 - Key with radio capsule

❑ Adaptation with radio re‐
mote control
⇒ page 75 .
❑ Individual radio capsu‐
les cannot be replaced
2 - Eye
❑ For key ring
3 - Battery
⇒ page 79
4 - Cover

system, vehicles from 06.2010
2.22.1 Removing
– Insert a small screwdriver in the gap between cap -1- and key
-2-.
– Turn the screwdriver in -direction of arrow- and prise cap -1-
off key -2-.
2. Front door 79
Phaeton 2003 ➤
– Unclip battery -1- from key -2- with a screwdriver in direction

of -arrow-.
2.22.2 Installing
Note
♦ Before installing battery, always press any key once.

♦ Thus transmitter unit is reset and can recognize a new battery
only now.
Note polarity and correct position when installing battery.

– Insert battery -1- in key -2- in -direction of arrow- with the pos‐
itive pole at top.
– Press lightly on the battery to engage it in the key.
– Now fit cover to the key.

Phaeton 2003 ➤
58 – Rear doors, door components

On the Phaeton, the doors, the rear lid and the bonnet are made
of aluminium. When these parts are installed, special care must
be taken regarding contact corrosion.
part.
WARNING

warranty.
1. Contact corrosion! 81
Phaeton 2003 ➤
2 Rear door
2.1 Tools

equipment required
♦ Socket -T 10072-
♦ Assembly tool -T 10118-
♦ Roller -3356-
♦ Torque wrench -5…50 Nm
V.A.G 1331-
82 Rep. gr.58 - Rear doors, door components

Phaeton 2003 ➤
2.2 Assembly overview - rear door
Note
♦ Spacer plates are located behind the upper door hinge and the door. The spacer plates have varying thick‐
nesses. Consequently, the door hinge must be loosened only on rare occasions.
♦ The hinge bolts must always be renewed if loosened.
1 - Door
⇒ page 84
❑ M8×28
(90°).
loosening.
❑ Remove only this bolt
from hinge to remove
door.
❑ M8×28
(90°).
loosening.
4 - Door hinge with arrester
❑ Hinge is split.
❑ M8×28
❑ Installed from inside ve‐
hicle.
❑ Removing A-pillar lower
trim ⇒ General body re‐
pairs, interior; Rep. gr.
70 ; Pillar and side panel
trim
(90°).
loosening.
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
7 - Hexagon nut
❑ 23 Nm
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
2. Rear door 83
Phaeton 2003 ➤
9 - Door hinge
❑ Hinge is split.
❑ M8×22
❑ Installed from inside vehicle.
❑ To loosen or tighten bolt, remove and install dash panel ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel; Removing and installing dash panel .
❑ 20 Nm + 1/4 turn further (90°).
11 - Hexagon nut
❑ 23 Nm
❑ M8×28
❑ 20 Nm + 1/4 turn further (90°).
13 - Door hinge
❑ Hinge is split.
14 - Spacer plate
❑ With material thicknesses of 0.5 mm, 1.0 mm and 1.5 mm.
2.3 Removing and installing door
2.3.1 Removing
– Remove B-pillar lower trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Pillar and side panel trim
– Unbolt seat belt height adjustment motor V233 -1-.
– Separate connectors -2- and unclip wiring harness.

Phaeton 2003 ➤
– Pull boot -3- off B-pillar. Now electrical wiring can be guided
out of B-pillar.
– Remove nuts -1- from door hinges and remove bolt -2- from
hinge.
Specified torque = 20 Nm + 1/4 turn (90°) further
Note
Always renew this bolt.
– Lift door upwards out of hinge brackets.
2.3.2 Installing
2.4 Adjusting door

To achieve correct door adjustment, spacer plates of various
thicknesses can be placed under the upper door hinge. Other
measures such as raising the door have no effect. Subsequent
pressure from above will cause the door to sack again.
Note
♦ Spacer plates -3- of various thicknesses are installed between

the upper door hinge -2- and the door.
♦ Before adjusting gap by moving upper door hinge, gap can be
altered by inserting a different spacer.
ing on its wheels.
♦ The front door is adjusted correctly if the gaps/shut lines are
even all around, the door is not too deep or does not stand
proud and all contours align when the is door closed.
♦ To adjust or check the gap dimensions ⇒ Body Repairs; Rep.
♦ After reinstalling or adjusting, carry out corrosion protection
measures to hinges and bolts.
Location of spacer plates -3- is shown in figure.

Door hinge bolts -1- must always be renewed.
Only if this adjustment is not sufficient should you move door
hinge on B-pillar.
2. Rear door 85
Phaeton 2003 ➤
2.5 Adjusting striker pin
Note

ing on its wheels.
♦ Only the adjustment for the right front door is described. The
adjustment of the left front door is similar.
♦ The rear door must lock fully when closing without any addi‐
tional force being required and must not have any play.
♦ The rear door must not be pushed up or down as a result of
the striker pin adjustment.
The following can be adjusted at the striker pin:

• When the rear door does not align with the rear side panel.
– Release the striker pin -1- by loosening bolts -2- at the C-pillar.
– Adjust rear door with striker pin -1- so that rear door is flush
with rear side panel when shut (to avoid wind noise).
– Tighten bolts -2- of striker pin -1-.
2.6 Assembly overview - door handle and door lock

Phaeton 2003 ➤
1 - Door lock
❑ The door lock can be re‐
moved only together
with the assembly carri‐
er.
⇒ page 91
❑
2 - Cable
❑ Lock release
3 - Bowden cable
❑ Bolted and riveted to
door lock.
❑ Not supplied with door
lock.
5 - Bearing bracket
❑ Removing:
Door handle, lock cylinder
housing and door assembly
carrier have been removed.
❑ Remove bolt -6-, slide
bearing plate -5- slightly
to rear and remove from
door.
6 - Bolt
7 - Base
8 - Door handle
⇒ page 88
❑ Door handle with (Key‐
less Entry) cable routing ⇒ page 90 .
9 - Housing
❑ Removing ⇒ Removing lock cylinder housing on page ⇒ page 61
10 - Base
❑ This screw has been replaced by a Torx screw. The new tool was introduced as a result.
❑ Socket wrench -T 10072- .
❑ Loosening this bolt releases the catch for housing -9-, which can then be withdrawn from the bearing
bracket -5-.
❑ Screw -11- must not be screwed in without the lock cylinder housing being inserted. Otherwise the locking
ring may fall into the door.
2. Rear door 87
Phaeton 2003 ➤
2.7 Removing and installing door handle
2.7.1 Removing
– Pull off door seal -1- in area of door handle.
– Pull door handle -2- in -direction of arrow- and hold.
– Unscrew bolt -4- onto stop using socket insert -T 10072- . This
releases the lock cylinder housing.
– Door handle with (Keyless Entry) cable routing ⇒ page 90 .
Note
Unscrewing the bolt too far may cause the locking ring to release
from the bearing bracket and fall into the door.
– Pull housing -3- at right angle to door out of door handle bear‐
ing plate.

– Swing door handle out of door.
2.7.2 Installing

Phaeton 2003 ➤
– Guide assembly tool -T 10118- into door through opening in

door inner panel.
– Use a hand torch to illuminate inside of door for improved vis‐
ibility.
– Hook assembly tool in spring -arrow A-.
– Hook spring into door lock by pulling assembly tool
-arrow B-.
The release lever is now secured.
2. Rear door 89
Phaeton 2003 ➤
– Swing door handle into door.

– Pull clip -1- into opening in panel and engage it in door handle
-2-.
Note
Press door handle -2- against door panel when assembling.
– Fit housing in door handle bearing plate at right angle.

– Now screw bolt into bearing bracket with assembly tool -T
10034- .
The door handle engages in housing again with an audible click.
Note
During assembly, the door handle and housing should be pressed

against the door panel.
– Pulling door handle unlocks the release lever.

• Afterwards, the function must be checked, as an incorrectly
fitted and adjusted Bowden cable cannot open the door.
– Install door seal in vicinity of door handle.
2.8 Door handle with (Keyless Entry) cable routing

Phaeton 2003 ➤
1 - Door
3 - Connector (Keyless Entry)
4 - Wiring harness
❑ Secured in upper door
area with cable tie.
❑ Removing assembly
carrier -2- ⇒ page 91 .
2.9 Removing and installing door lock

assembly carrier.
The door lock can be removed only together with the assembly
carrier.
2.9.1 Removing
– Remove rear door trim and carrier frame ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Removing and installing door trim .
2. Rear door 91
Phaeton 2003 ➤

– Pull door handle -2- in direction of arrow and hold. Unscrew
bolt -4- onto stop using socket insert -T 10072- . This releases
the lock cylinder housing.
Note
Unscrewing the bolt too far may cause the locking ring to release
from the bearing bracket and fall into the door.
ing plate.
– Remove bolts -1-.

Phaeton 2003 ➤
Note

sive tape).

– Separate connectors -3- and unclip from assembly carrier.

– Lever door lock with retaining bracket off assembly carrier us‐
ing a screwdriver.
Note
2. Rear door 93
Phaeton 2003 ➤

it from the eye.
2.9.2 Installing

– Using a screwdriver, tension the spring -2- mounted on the
door lock in the direction of the arrow and attach the lock lever
to the spring.

Phaeton 2003 ➤
Note

al.
2.10 Assembly overview - door power latching motor (V 278)
2. Rear door 95
Phaeton 2003 ➤
1 - Door
3 - Bolt
❑ Qty. 4
❑ 3.5 Nm
4 - Door power latching motor
(V 278)
5 - Connector
6 - Bowden cable
2.11 Door seals

During production, a sealant is applied to the door seals, which
are then placed on the door flange and rolled on.
Note
♦ When seals are removed, the sealant will spread to the inside
of the seal and the flanks will be bent out slightly. If the seal is
then refitted, a tight seal is not guaranteed.
♦ Therefore each seal which is removed completely should be
replaced by a so-called „tap-on“ seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.

Phaeton 2003 ➤
2.12 Removing and installing door inner seal
2.12.1 Removing
– Remove the pillar trims as required ⇒ General body repairs,
interior; Rep. gr. 70 ; Pillar trim
– Remove sill panel mouldings ⇒ General body repairs, interior;
Rep. gr. 68 ; Interior equipment; Sill panel mouldings .
– Remove interior door seal from body flange.
2.12.2 Installing
– When installing door inner seal, start at upper radius of the
door aperture.
2.13 Removing and installing door outer seal
Note
♦ The description of removal and installation is only for the right

door outer seal. The removal and installation of the left door
outer seal is similar.
Working temperature about 20 °C.
♦ Use only adhesive remover D 002 000 10.
♦ The door outer seal must be bonded in place immediately after
cleaning.
2.13.1 Removing
– To remove door outer seal, door trim, both carrier frames and
window frame trim must be removed ⇒ General body repairs,
interior; Rep. gr. 70 ; Removing and installing door trim .
– Pull door outer seal off door flange.
2. Rear door 97
Phaeton 2003 ➤
2.13.2 Installing
– Remove existing adhesive residues with erasure disc of ad‐
hesive strip remover -VAS 6349- .
– Immediately before bonding door outer seal, clean bonding
surface thoroughly with adhesive remover D 002 000 10.
• Bonding surfaces must be free of dust and grease and there
should be no adhesive residues.
– To apply door outer seal, align coloured mark of seal with se‐
curing bolt -1- of window slot seal.
– Pull protective sheeting off in stages, then apply seal to door
flange and press. Do not pull door outer seal to avoid stretch‐
ing seal.

Phaeton 2003 ➤
– Press complete bonding surface of seal -3- on door -1- all

around using roller -3356- .
– To do this, push the seal aside -arrow a- so that the roller
-3356- runs directly over the contact surface of the seal.
The roller can apply the necessary force -arrow b- to the bonding
surface -2- only when procedure described above is followed.
– If the seal has stretched, cut seal to required length and press
on butt joint well.
– If seal -3- comes loose in small areas again, press seal on well
again using roller -3356- .
Note
The door must not be closed for a period of 2 hours to ensure the door outer seal does not move or loosen
again.
2.14 Door insulation
Note
♦ The insulation elements have the task of minimising noise and ensuring good sealing qualities. For this
reason, it is important to ensure that only serviceable insulation elements are installed and in the correct
position.
♦ The bonded insulation elements should always be renewed.
♦ Inserted damping parts are to be checked for damage, e.g. cracks, and renewed if necessary.
2. Rear door 99
Phaeton 2003 ➤
1 - Door
2 - Insulation
❑ Inserted in upper area of
B-pillar.
3 - Sealing strip
❑ Bonded to B-pillar.
❑ Self-adhesive.
4 - Insulation
⇒ page 100
5 - Sound suppression
❑ Self-adhesive.
6 - Insulation
❑ Mounted on centre
cross member.
7 - Insulation
❑ Inserted in C-pillar.
8 - Decorative film
❑ For bottom area.
9 - Decorative film
❑ For upper area.
10 - Insulation
❑ Inserted in bottom area
of C-pillar.
2.15 Installing insulation

– The insulation elements -1- are inserted in the inner -2- and
outer -3- support panel.

Phaeton 2003 ➤
60 – Sunroof
1 Sunroof with glass panel
1.1 Tools
♦ Vehicle diagnostic, testing and information system -VAS 5051-
1.2 Function
All functions of the sliding/tilting sunroof with glass panel can be
performed with ignition switched on.
After ignition is switched off, the functions can be performed until
either the driver or front passenger door is opened.
1. Sunroof with glass panel 101

Phaeton 2003 ➤
The opening of the glass panel in sliding or tilting positions can

be preselected using the rotary switch -1-. The sunroof roller blind
has its own drive. Operating the rotary switch simultaneously ac‐
tuates the drives for the sliding/tilting sunroof and for the sunroof
roller blind, setting them in motion.
By means of switch -2- (close sunroof roller blind) and switch
-3- (open sunroof roller blind) next to rotary switch, the sunroof
roller blind can be moved independently of the glass panel.
The wind deflector also has its own drive. This drive extends the
wind deflector depending on the opening position of the glass
panel as well as the vehicle speed. When the vehicle is being
driven, a gap may develop between the vehicle roof and the wind
deflector. This intentional gap reduces noise.
All electrically driven sliding/tilting sunroof components are fitted
with an anti-trap circuit. The glass panel ??? from its tilted posi‐
tion.
In addition, there is an emergency closure function. If problems
occur during closure, the sunroof can be forced to shut by press‐
ing the pre-selector switch when it is in the „close sunroof“ posi‐
tion.
The anti-trap mechanism works with raised clamping forces in the
emergency closure function.
The sunroof drive is protected against overheating by a time lim‐
itation. The protective mechanism activates when the sunroof is
operated continuously for approx. 2 minutes. It is functional again
after a cooling-off phase.
In the event of power failure, the sunroof can be moved using a
crank directly on the drive. This crank is attached to the inside of
the rear interior light trim.
1.3 Assembly overview
102 Rep. gr.60 - Sunroof

Phaeton 2003 ➤
1 - Carrier unit
❑ Removing carrier unit
⇒ page 117 .
❑ U-frame with guide
channels: grease guide
channels as required
with special grease G
000 450 02 only. Other‐
wise correct operation
cannot be guaranteed.
2 - Slide with cable
❑ For guide plate.
❑ Cables cannot be re‐
newed separately, but
only together with the
assembly unit.
❑ For sun visor.
assembly unit.
4 - Wind deflector mounting
5 - Wind deflector
6 - Bolt
7 - Cover
8 - Sliding headliner
sliding headliner
⇒ page 108
9 - Cover
10 - Guide plate
❑ Part of assembly unit. Cannot be renewed separately.
11 - Glass panel for sliding/tilting sunroof (single pane safety glass)
❑ Removing sliding/tilting sunroof glass panel ⇒ page 104 .
❑ Installing sliding/tilting sunroof glass panel ⇒ page 104 .
❑ Adjusting sliding/tilting sunroof glass panel ⇒ page 105
❑ Renewing panel seal ⇒ page 107 .
13 - Drive for sliding/tilting sunroof
❑ Check drive (0 position) ⇒ page 111 .
14 - Water channel
15 - Crank for emergency operation
❑ Clipped into cover for electric drive.
16 - Drive for sunroof roller blind

Phaeton 2003 ➤
17 - Electrical wiring
18 - End piece
19 - Bolt
21 - Wind deflector drive
22 - Bolt
23 - Extender mechanism
❑ For wind deflector.
24 - Seal
❑ For assembly unit.
1.4 Removing sliding/tilting sunroof glass

panel
– Raise sliding/tilting sunroof
– Move sunroof roller blind to rear.
– Unclip the pleated blind from the bottom strip, starting at the
rear
– Unclip the pleated blind from the top strip, starting at the front
– Push the pleated blind rearwards -arrow- out of the oblong
hole, and remove it.
– Remove securing bolts -1-.

– Lift out sliding/tilting sunroof.
1.5 Installing sliding/tilting sunroof glass

panel
Panel must be installed in the zero position (panel closed).

Phaeton 2003 ➤
Zero position:
The guide pins -1- must lie between the markings on the guide
plate -arrow-.
If this is not the case, adjust parallel running ⇒ page 106 .
– Place sunroof panel on from above and screw in securing

screws (guide plate to panel).
– Loosely tighten securing bolts -arrows-.
Note
After adjusting panel height, tighten securing screws 4.5 Nm.
– Adapt components ⇒ page 121
1.6 Adjusting height of sliding/tilting sunroof

glass panel
Sliding/tilting sunroof zero position OK.
– Tilt glass panel.
– Push back sunroof roller blind as far as it can go.
– Unclip the pleated blind from the bottom strip, starting at the
rear
– Unclip the pleated blind from the top strip, starting at the front
– Move glass panel to zero position.
– To prevent wind noises, carry out front and rear height adjust‐
ment in accordance with illustrations.
Front panel adjustment:

a = 0 to 1 mm lower than roof line
-Arrow- = Forwards

Phaeton 2003 ➤
Rear panel adjustment:

b = 0 to 1 mm higher than roof line
-Arrow- = Forwards
– Tighten screws for glass panel 4.5 Nm.
1.7 Checking parallel running of glass panel

– Tilt glass panel.
– Push back sunroof roller blind as far as it can go.
– Unclip the pleated blind at the bottom, starting at the rear.
– Unclip the pleated blind at the top strip, starting at the front.
– Move glass panel to zero position.
Guide pin -1- must be located between markings -arrow- on left

and right guide plates.
1.8 Adjusting parallel running of glass panel
Note
Parallel running adjustment can only be undertaken when the

drive and solar panel are removed while in "0" position.
– Slide guides from front to rear only.

Phaeton 2003 ➤

– Reinstall drive and glass panel.
1.9 Renewing panel seal

– Removing glass panel for sunroof ⇒ page 104 .
– Pull seal -1- off glass panel.
– Press new seal into groove in glass panel -2-.
Note
To ease fitting of seal, coat panel edge with a soapy solution.
1.10 Removing and installing wind deflector
1.10.1 Removing
– Open sunroof completely.
– Applying force on left and right about 20 cm inwards measured
from roof cut-out -arrows-, push wind deflector backwards.
Lever out both retaining brackets below positioning mecha‐
nism -1- for wind deflector and lift out of roof edge.

Phaeton 2003 ➤
– Raise wind deflector to vertical and remove to rear from re‐

taining clips on left and right.
– Remove the wind deflector.
1.10.2 Installing
1.11 Adjusting wind deflector

– Wind deflector seal must lightly contact edge of roof without
detectable gap -arrow-.
– It should just be possible to pull a piece of paper between wind
deflector and edge of roof.
– Loosen bolts -1- to make adjustment. Push left and right wind
deflector retaining brackets -2- as necessary to position them.
1.12 Removing and installing sliding headlin‐

er
1.12.1 Removing
– Removing glass panel for sunroof ⇒ page 104 .
– Move sliding headliner forwards as far as possible.

Phaeton 2003 ➤
– Remove bolts -2- and remove trim -1- upwards.
1.12.2 Installing
1.13 Adjusting parallel running of sliding headliner

Phaeton 2003 ➤
Removing sliding/tilting sunroof glass panel ⇒ page 104 .

Move sliding headliner forwards so that a measurable gap -
dimension a- is created.
-Dimension a- must be identical on left and right sides.
If this is not the case, remove drive for sliding headliner.
Position sliding headliner so that -dimension a- is identical on left
and right.
Install drive for sliding headliner in this position.
1.14 Removing and installing sliding/tilting

sunroof drive
1.14.1 Removing
– Switch off ignition.

Phaeton 2003 ➤
– Using a small screwdriver, release the locking mechanism at

the front -arrows- of the cover of the rear light and control unit.
– Remove three bolts -arrows-.

– Remove rear light and control unit and separate connector.
Note
Remove and install drive for sliding/tilting sunroof only when roof
is closed ("0" position).
– Remove bolts -2- and pull off drive -1- for sliding/tilting sunroof.
– Unclip and separate connector -3-.
The screws for the drive are microencapsulated and must always
be renewed 3.5 Nm.
1.14.2 Installing
1.15 Adjusting drive for sliding/tilting sunroof

(zero position)
Drive removed but still connected electrically.
– Switch on ignition.
– Select „close sunroof“ using preselection control rotary switch.
– Drive automatically runs to zero position and switches off.

Phaeton 2003 ➤
– The viewing hole is protected by a cover. Lever off cover -1-.

– The coloured marking -2- in viewing hole and protruding lug
-3- must align.
– Install drive in this position (zero position) with sunroof closed.
1.16 Removing and installing drive for sliding

headliner
1.16.1 Removing


Phaeton 2003 ➤
– Remove bolts -2- and pull off drive for sliding headliner -1-.
– Unclip and separate connector.
be renewed 3.5 Nm.
1.16.2 Installing

drive
1.17.1 Removing
– Using a small screwdriver, release interior light glass locking
mechanism in front -arrow- of front lights and operating unit.
– Remove both bolts -arrows-.

– Remove front lights and operating unit and disconnect con‐
nector.

Phaeton 2003 ➤
– A securing bolt is located in cut-out for lights and operating unit

on wind deflector drive.
– Outer securing bolt -arrow- for wind deflector drive is located

in the centre of front edge of sliding roof aperture between
edge of roof and moulded headliner.
– Remove bolt -arrow- and pull off wind deflector drive inwards.
be renewed 3.5 Nm.
1.17.2 Installing

sunroof automatic preselector
1.18.1 Removing

Phaeton 2003 ➤

– Remove two bolts -arrows-.

– Remove front light and control unit and separate connector.
– On the back of the light and control unit, the rectangular com‐
ponent is first unclipped and swung to side.
– Release the three locking mechanisms -arrows- and press out

rotary switch by hand from front.
1.18.2 Installing

Phaeton 2003 ➤
1.19 Removing switches for sunroof roller

blind
1.19.1 Removing

ponent is first unclipped -arrows- and swung to side.
– Remove four bolts -arrows- for one of the two reading lights
and remove reading light.

Phaeton 2003 ➤
– Remove the six bolts from printed circuit board.

– Remove the circuit board with the switches for the sunroof
roller blind.
1.19.2 Installing
1.20 Removing and installing carrier unit
1.20.1 Removing

Phaeton 2003 ➤
– Remove moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70 ; Trim, insulation; Roof trims .
– Pull connectors -4- off installed drives.
– Pull water drain hoses off carrier unit.
– Remove hexagon bolts -3- and lift carrier unit -1- out of vehicle
with help of second mechanic.
1.20.2 Installing
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– Using cylindrical dowel pins (inverted drill bits) align the carrier
unit 10 mm from the roof frame at the front right -5- and 12 mm
at the front left -2-. Carrier unit must not contact roof frame.
– Check routing of wiring and connections of electrical consum‐
ers in roof and restore if necessary.
– Tighten bolts to 8 Nm for carrier unit -1-, starting at tilting/slid‐
ing sunroof drive -4- and moving towards the rear, alternating
between the left and right-hand side.
– Remove cylindrical pins -2- and -5-.

Phaeton 2003 ➤
– Fit water drain hoses.

– Fit connector for drives -4-.
1.21 Operating without current

– Release cover for rear light and control unit.
– A crank is clipped into cover for rear light and control unit.
– Insert crank in bolt of drive and push upwards -arrow-.

– The bolt will be pressed a few millimetres inwards -a-. The
sliding/tilting sunroof panel can only be moved in this position.
1.22 Cleaning water drain hoses
1.22.1 Front water drain hoses

Phaeton 2003 ➤
The front water drain hoses run through the A-pillars and end at
the engine bulkhead. Cleaning is done from the sunroof panel
aperture.
Note
For cleaning, a locally manufactured tool made from a speedometer inner cable, approx. 2300 mm long is
recommended.

Phaeton 2003 ➤
1.22.2 Rear water drain hoses
The rear water drain hoses run through the C-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.
Note
recommended.
1.23 Adapting components of sliding/tilting

sunroof
Adapting (standardisation) the components entails two steps
which must be performed one immediately after the other.
The first step is initialisation. In this case, the zero positions are
determined as reference points for travel.
The second step is teach-in. In this case, the running character‐
istics are measured to optimise the anti-trap circuit

Phaeton 2003 ➤
– Turn rotary switch to zero position. If a drive begins to run, wait

for it to stop.
– Initiate emergency closing function by pressing rotary switch,
and hold it pressed.
– Initialisation begins within a few seconds. If noises can be
heard from the wind deflector drive, release rotary switch im‐
mediately.
– First stage of initialisation complete.
– Start teach-in phase immediately after initialisation.
– Press and hold rotary switch again.
– Within a few seconds the panel moves to the tilted position,
returns and then opens completely in the sliding position.
– The panel moves first to tilt position, then to zero position and
stops. The sliding headliner also returns to the zero position
with a slight time delay.
– Release the rotary switch after the sliding headliner has stop‐
ped.
– Ignition may not be switched off until at least 5 seconds have
elapsed.
The system is normed, ready for operation and anti-trap circuit is
active.
1.24 Coding sliding/tilting sunroof

Sliding/tilting sunroof is coded with vehicle diagnosis, testing and
information system -VAS 5051- .
♦ Body (Rep. Gr. 01; 27; 50…97)
♦ General body repairs (Rep. Gr. 01; 50…77)
♦ Roof electronics
♦ Roof electronics functions

Phaeton 2003 ➤
2 Remove sliding/tilting sunroof with

solar panel
2.1 Tools
♦ Vehicle diagnostic, testing and information system -VAS 5051-
2.2 Function
All the movement functions of the sliding/tilting sunroof with solar
panel can be carried out with the ignition switched on.
After the ignition is switched off, actions can be performed until
either the driver or front passenger door is opened.
2. Remove sliding/tilting sunroof with solar panel 123

Phaeton 2003 ➤
Opening the solar panel in the sliding and tilting positions is pre‐
selected with the rotary switch. The panel covering is an integral
part of the solar panel and cannot be moved separately.
The wind deflector also has its own drive. This drive extends the
wind deflector depending on the opening position of the solar
panel as well as the vehicle speed. When the vehicle is being
driven, a gap may develop between the vehicle roof and the wind
deflector. This intentional gap reduces noise.
All electrically driven sliding/tilting sunroof components are fitted
with an anti-trap circuit. The glass panel ??? from its tilted posi‐
tion.
In addition, there is an emergency closure function. If problems
occur during closure, the sunroof can be forced to shut by press‐
ing the pre-selector switch when it is in the „close sunroof“ posi‐
tion.
The anti-trap mechanism works with raised clamping forces in the
emergency closure function.
The sunroof drive is protected against overheating by a time lim‐
itation. The protective mechanism activates when the sunroof is
operated continuously for approx. 2 minutes. It is functional again
after a cooling-off phase.
In the event of power failure, the sunroof can be moved using a
crank directly on the drive. This crank is attached to the inside of
the rear interior light trim.
The solar cells -1- integrated in the solar panel of the sliding/tilting
sunroof generate a high voltage when exposed to the sun. The
DC converter -2- incorporated in the solar panel provides a suit‐
ably modified voltage for the vehicle fan. This only works when
the ignition is switched off and the solar panel is tilted or closed.
2.3 Assembly overview

Phaeton 2003 ➤
1 - Carrier unit
❑ Removing carrier unit
⇒ page 136 .
❑ U-frame with guide
channels: grease guide
channels as required
with special grease G
000 450 02 only. Other‐
wise correct operation
cannot be guaranteed.
assembly unit.
❑ For sun visor.
❑ Not installed with solar
panel.
4 - Wind deflector mounting
❑ For panel trim.
6 - Wind deflector
7 - Bolt
8 - Cover
9 - Panel covering
panel covering
⇒ page 130
10 - Solar contact
❑ On panel.
11 - Cover
❑ Not installed with solar panel.
12 - Guide plate
13 - Solar panel for sliding/tilting sunroof (single pane safety glass)
❑ Remove sliding/tilting sunroof solar panel ⇒ page 126 .
❑ Installing the sliding/tilting sunroof solar panel ⇒ page 126 .
❑ Adjusting the sliding/tilting sunroof solar panel ⇒ page 127 .
❑ Renewing panel seal ⇒ page 129 .
14 - DC-DC converter
16 - Drive for solar panel
❑ Adjusting drive ("0" position) ⇒ page 132 .
17 - Water channel

Phaeton 2003 ➤
18 - Crank for emergency operation

❑ Clipped into cover for electric drive.
20 - End piece
21 - Bolt
23 - Wind deflector drive
24 - Bolt
25 - Extender mechanism
❑ For wind deflector.
26 - Solar contact
❑ On carrier unit.
27 - Seal
❑ For assembly unit.
2.4 Removing sliding/tilting sunroof solar

panel
– Open sliding/tilting sunroof about 10 cm rearwards.
– Pull trim -1- downwards in the middle -arrow- out of mounting
-2-.
– Push the trim rearwards.
– Raise sliding/tilting sunroof
– Remove securing bolts -1- from (guide/panel) -3-.

– Remove sunroof panel -2- upwards.
2.5 Installing sliding/tilting sunroof solar

panel
Panel must be installed in the zero position (panel closed).

Phaeton 2003 ➤
Zero position:
The guide pins -1- must lie between the markings on the guide
plate -arrow-.
If this is not the case, adjust parallel running ⇒ page 128 .
– Insert the sliding/tilting sunroof panel from above and tighten

the mounting screws -arrows- (guide plate/panel).
– Loosely tighten securing bolts -arrows-.
Note
After adjusting panel height, tighten securing screws 4.5 Nm.
2.6 Adjusting sliding/tilting sunroof solar

panel height
-2-.
– Run solar panel to zero position.
– To avoid wind noise, adjust the solar panel height front and
rear as shown in the illustration.
Front panel adjustment:

a = 0 to 1 mm lower than roof line
-Arrow- = Forwards

Phaeton 2003 ➤
Rear panel adjustment:

b = 0 to 1 mm higher than roof line
-Arrow- = Forwards
– Tighten screws of solar panel 4.5 Nm.
2.7 Checking parallel running of solar panel

-2-.
– Run solar panel to zero position.

2.8 Adjusting parallel running of solar panel
Note
Parallel running adjustment can only be undertaken when the

drive and solar panel are removed while in "0" position.
– Slide guides from front to rear only.

Phaeton 2003 ➤

– Refit the drive and solar panel.
2.9 Renewing panel seal

– Removing the sliding/tilting sunroof solar panel ⇒ page 126 .
– Detach seal -1- from solar panel.
– Press the new seal into solar panel -2-.
Note
To ease fitting of seal, coat panel edge with a soapy solution.
2.10.1 Removing
– Applying force on left and right about 20 cm inwards measured
from roof cut-out in -direction of arrows-, push wind deflector
backwards. Lever out both retaining brackets below position‐
ing mechanism -1- for wind deflector and lift out of roof edge.

Phaeton 2003 ➤
– Raise wind deflector to vertical in -direction of arrow- and re‐

move to rear from retaining clips on left and right.
– Remove the wind deflector.
2.10.2 Installing
2.11 Adjusting wind deflector

– Wind deflector seal must lightly contact edge of roof without
detectable gap -arrow-.
– It should just be possible to pull a piece of paper between wind
deflector and edge of roof.
– Loosen bolts -1- to make adjustment. Push left and right wind
deflector retaining brackets -2- as necessary to position them.
2.12 Removing and installing solar panel trim
2.12.1 Removing
-2-.
– Push trim forwards.
– Move sliding/tilting sunroof back.

Phaeton 2003 ➤
– Remove bolts -2- and remove trim -1- upwards.
2.12.2 Installing

sunroof drive
2.13.1 Removing

Note
Remove and install drive for sliding/tilting sunroof only when roof
is closed ("0" position).

Phaeton 2003 ➤
– Remove bolts -2- and pull off drive -1- for sliding/tilting sunroof.
– Unclip and separate connector -3-.
be renewed 3.5 Nm.
2.13.2 Installing
2.14 Adjusting drive for sliding/tilting sunroof

(zero position)
Drive removed but still connected electrically.
– Select „close sunroof“ using preselection control rotary switch.
– Drive automatically runs to zero position and switches off.
– The viewing hole is protected by a cover. Lever off cover -1-.
– The coloured marking -2- in viewing hole and protruding lug
-3- must align.
– Install drive in this position (zero position) with sunroof closed.

drive
2.15.1 Removing

Phaeton 2003 ➤

– Remove both bolts -arrows-.

– Remove front lights and operating unit and disconnect con‐
nector.
– A securing bolt is located in cut-out for lights and operating unit

on wind deflector drive.

Phaeton 2003 ➤
– Outer securing bolt -arrow- for wind deflector drive is located

in the centre of front edge of sliding roof aperture between
edge of roof and moulded headliner.
– Remove bolt -arrow- and pull off wind deflector drive inwards.
be renewed 3.5 Nm.
2.15.2 Installing

sunroof automatic preselector
2.16.1 Removing


Phaeton 2003 ➤
ponent is first unclipped -arrows- and swung to side.
– Release the three locking mechanisms -arrows- and press out

rotary switch by hand from front.
2.16.2 Installing
2.17 Removing and installing DC-DC con‐

verter
2.17.1 Removing
– Remove the four bolts -4- for retaining braces -6-.
– Remove retaining braces.
– Pull connector off DC-DC converter -7-.
2.17.2 Installing
2.18 Removing solar contact


Phaeton 2003 ➤
– Tip solar contact -2- with bracket and remove from retainer.
– Pull connector off DC-DC converter.
2.19 Removing and installing carrier unit
2.19.1 Removing

– Remove moulded headlining ⇒ General body repairs, interior;
Rep. gr. 70 ; Roof trim

Phaeton 2003 ➤
– Pull connectors -4- off installed drives.

– Pull water drain hoses off carrier unit.
– Remove hexagon bolts -3- and lift carrier unit -1- out of vehicle
with help of second mechanic.
2.19.2 Installing
– Fit carrier unit -1- into roof aperture with the help of a second
mechanic.
– Using cylindrical dowel pins (inverted drill bits) align the carrier
unit 10 mm from the roof frame at the front right -5- and 12 mm
at the front left -2-. Carrier unit must not contact roof frame.
– Check routing of wiring and connections of electrical consum‐
ers in roof and restore if necessary.
– Tighten bolts to 8 Nm for carrier unit -1-, starting at tilting/slid‐
ing sunroof drive -4- and moving towards the rear, alternating
between the left and right-hand side.
– Remove cylindrical pins -2- and -5-.
– Fit water drain hoses.
– Fit connector for drives -4-.

Phaeton 2003 ➤
2.20 Operating without current

– Release cover for rear light and control unit.
– A crank is clipped into cover for rear light and control unit.
– Insert crank in bolt of drive and push upwards in

-direction of arrow-.
– The bolt will be pressed a few millimetres inwards -a-. The
sliding/tilting sunroof panel can only be moved in this position.
2.21 Cleaning water drain hoses
2.21.1 Front water drain hoses

Phaeton 2003 ➤
The front water drain hoses run through the A-pillars and end at
the engine bulkhead. Cleaning is done from the sunroof panel
aperture.
Note
recommended.

Phaeton 2003 ➤
2.21.2 Rear water drain hoses
The rear water drain hoses run through the C-pillars and end in
the rear wheel housings. Cleaning is done from the wheel hous‐
ing. The wheel housing liner must be removed.
Note
recommended.
2.22 Adapting components of sliding/tilting

sunroof
Adapting (standardisation) the components entails two steps
which must be performed one immediately after the other.
The first step is initialisation. In this case, the zero positions are
determined as reference points for travel.
The second step is teach-in. In this case, the running character‐
istics are measured to optimise the anti-trap circuit

Phaeton 2003 ➤
– Turn rotary switch to zero position. If a drive begins to run, wait

for it to stop.
– Initiate emergency closing function by pressing rotary switch,
and hold it pressed.
– Initialisation begins within a few seconds. If noises can be
heard from the wind deflector drive, release rotary switch im‐
mediately.
– First stage of initialisation complete.
– Start teach-in phase immediately after initialisation.
– Press and hold rotary switch again.
– Within a few seconds the panel moves to the tilted position,
returns and then opens completely in the sliding position.
– The panel returns, moves to the tilt position first, then to the
zero position and stops.
– Release the rotary switch after the panel has stopped in the
zero position.
– Ignition may not be switched off until at least 5 seconds have
elapsed.
The system is normed, ready for operation and anti-trap circuit is
active.
2.23 Coding sliding/tilting sunroof

Sliding/tilting sunroof is coded with vehicle diagnosis, testing and
information system -VAS 5051- .
♦ Body (Rep. Gr. 01; 27; 50…97)
♦ General body repairs (Rep. Gr. 01; 50…77)
♦ Roof electronics
♦ Roof electronics functions

Phaeton 2003 ➤
63 – Bumpers
1 Front bumper cover of vehicles up to
05.2010
1.1 Repairing front bumper cover
Note
If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper ⇒ General Information; Body
Repairs, General Body Repairs ; Plastic repair process .
1.2 Tools
♦ Socket -T10113-
1.3 Assembly overview - front bumper cover
Note
There may be minor differences between bumper covers, depending on vehicle model.
142 Rep. gr.63 - Bumpers

Phaeton 2003 ➤
1 - Front bumper cover

⇒ page 143
❑ Material: PP/EPDM
2 - Bolt
❑ Qty. 6.
❑ 8 Nm
3 - Bolt
❑ 2 Nm
❑ Can be reached through
cut-out in wheel housing
liner with socket -
T10113- .
4 - Bolt
❑ 2 Nm
5 - Expanding nut
6 - Bolt
❑ 2 Nm
7 - Speed nut
8 - Cover for headlight washer
system
❑ Must be moved to latch‐
ing position in order to
remove front bumper
cover.
9 - Bolt
❑ 2 Nm
10 - Clip
❑ Qty. 3.
11 - Bolt
❑ 2 Nm
❑ Located behind cover parts.
1.4 Removing and installing front bumper

cover
Note
The removal and installation procedures for front bumper cover

may have to be revised slightly depending on model variations.
1. Front bumper cover of vehicles up to 05.2010 143

Phaeton 2003 ➤
1.4.1 Removing
– Unscrew bolts -2-.

– Bolts -11- are located under cover part ⇒ page 149 .
– Remove bolts -9- to wheel housing liner on lower side of front
bumper cover as well as clips -10- for attachment to lock car‐
rier.
– Remove bolts -4- and bolt inserted upwards -6- in wheel hous‐
ing.
– Move headlight washer system cover to rest position.
– Bolt -3- can be reached with the socket -T10113- through cut-
out in wheel housing liner.
– Pull front bumper cover parallel out of guides, with help of a
second mechanic.
– Disconnect the parking aid connector ⇒ Electrical system;
Rep. gr. 94 ; Parking aid; Removing and installing front park‐
ing aid sender
– Detach connectors of other installed electrical components.

Phaeton 2003 ➤
1.4.2 Installing
Observe sequence when tightening bolts.

– Bolt -3- is to be tightened first.
– Next the two outer bolts of bolt group -2- and then the inner
four.
– Bolt -6- (inserted upwards) in wheel housing and bolt -11- are
to be tightened next.
– The further sequence of bolts and clips is not specified.

Phaeton 2003 ➤
1.5 Front bumper cover add-on parts

⇒ page 143
2 - Impact absorber
❑ Self-adhesive.
3 - Side marker light
❑ Left and right.
❑ US vehicles only.
❑ Can be removed only
when front bumper cov‐
er has been removed ⇒
Vehicle electrics; Elec‐
trical system; Rep. gr.
94 ; Lights, bulbs,
switches - exterior; Re‐
moving and installing
side marker light bulb .
4 - Bumper strip
❑ Left and right.
❑ Clipped in front bumper
cover
❑ Can only be removed
with front bumper cover
removed
5 - Registration plate carrier
❑ Material PC/ABS
6 - Clip
❑ Qty. 5.
7 - Bumper cover insert
❑ Left and right.
❑ Exists in various ver‐
sions.
❑ Assembling ⇒ page 150
8 - Bolt
❑ Left and right.
❑ 2 Nm
9 - Spoiler
❑ Clipped in front bumper cover
❑ Can only be removed with front bumper cover removed
10 - Chrome strip
❑ Bonded in position with double-sided adhesive tape and additionally clipped
11 - Bumper strip
❑ Left and right.

Phaeton 2003 ➤
12 - Retaining clip
❑ For chrome strip
1.6 Front bumper cover substructure parts
1 - Front bumper carrier

2 - Bolt
❑ 20 Nm
⇒ page 10 .
3 - Bolt
❑ 50 Nm
⇒ page 10 .
4 - Bolt
❑ Qty. 3.
❑ 8 Nm
5 - Securing strip
6 - Bolt
❑ 8 Nm
7 - Guide
❑ Left and right.
❑ To remove and install,
pull out/push in front
bumper cover parallel to
guide elements (left and
right).
8 - Adjustment element
❑ Self-adjusting
❑ Must be screwed out as
far as possible before
front bumper cover is fitted.
9 - Bolt
❑ 8 Nm
❑ Left and right.
11 - Bolt
❑ 1 Nm
12 - Hexagon nut
❑ 8 Nm

Phaeton 2003 ➤
13 - Sender for right ACC -G259-

❑ Installation instructions ⇒ page 148 .
1.7 Installation notes for ACC sensor on

right -G259- / left -G 258-
Note


♦ every removal and installation or renewal of the ACC sensor
on right -G259-
♦ every removal and installation or renewal of the front bumper
carrier
♦ if there is reason to believe that a force has been exerted on
When installing the ACC sensor on the right -G259- , ensure that
the sensor does not touch the radiator located behind it.
A distance of 10 mm for adjustment work must be maintained
between the back of the sender and the radiator.
When installing the front bumper cover, ensure that the front
bumper cover does not touch the sensor.
Ensure that the radar-compatible cover is installed in the front
bumper cover.
The ACC sender on the right -G259- is adjusted with the ACC
setting device -VAS 6041- and the wheel alignment unit .
1.8 Removing and installing adaptive cruise

control sensor -ACC-
Note

In order to remove the ACC sensor on the right -G259- , the front
bumper cover must first be removed ⇒ page 143 .

Phaeton 2003 ➤
The ACC sender on the right -G259- -3- is located behind the front
bumper carrier -1-.
– Remove the 4 bolts -4- and detach connector -2-.
1.9 Removing and installing bumper cover insert
Note
For vehicles with automatic adaptive cruise control, ensure that corresponding radar-compatible bumper cover
insert is used.

Phaeton 2003 ➤
– Unscrew bolt -4-.

– Locking hook -3- must be released with screwdriver in direc‐
tion of -arrow a-; then cover section -1- can be pulled forwards
-arrow b- out of front bumper cover -2-.
1.10 Assembling bumper cover insert
Note
The bumper cover insert is available in different versions.

Phaeton 2003 ➤
– Engage grid -2- on bumper cover insert -1-. Ensure that all
retaining hooks engage correctly.
– Pull off protective backing from adhesive tape -3-.
– Engage chrome strip -4- on bumper cover insert -1-. Ensure
that all retaining hooks engage correctly.
– Press chrome strip -4- forcefully on bumper cover insert -1- in
area of adhesive tape -3-.
– Tighten bolts -5-. Specified torque: 2 Nm

Phaeton 2003 ➤
2 Front bumper cover of vehicles from

06.2010
2.1 Repairing front bumper cover
Note

repaired before renewing bumper ⇒ General Information; Body
Repairs, General Body Repairs ; Plastic repair process .
2.2 Tools
♦ Socket -T10113-
2.3 Assembly overview - front bumper cover
Note
There may be minor differences between bumper covers, depending on vehicle model.

Phaeton 2003 ➤

⇒ page 153
2 - Bolt
❑ Qty. 6.
❑ 4 Nm
3 - Cover for headlight washer
system
❑ Must be moved to latch‐
ing position in order to
remove front bumper
cover.
4 - Bolt
❑ 2 Nm
❑ Can be reached through
cut-out in wheel housing
liner with socket -
T10113- .
5 - Bolt
❑ 2 Nm
6 - Bolt
❑ 2 Nm
7 - Bolt
❑ 2 Nm
8 - Clip
❑ Qty. 3.
9 - Bolt
❑ 4 Nm
❑ Located behind cover parts.
2.4 Removing and installing front bumper

cover
Note
The removal and installation procedures for front bumper cover

may have to be revised slightly depending on model variations.
2. Front bumper cover of vehicles from 06.2010 153

Phaeton 2003 ➤
2.4.1 Removing

– The bolts -9- can be reached through the cover sections on
the left and right.
– Remove bolts -7- to wheel housing liner on lower side of front
bumper cover as well as clips -8- for attachment to lock carrier.
– Remove bolts -6- and bolt inserted upwards -5- in wheel hous‐
ing.
– Move cover for headlight washing system -3- to latching posi‐
tion.
– Bolt -4- can be reached with the socket -T10113- through cut-
out in wheel housing liner.
– Pull front bumper cover parallel out of guides, with help of a
second mechanic.
Rep. gr. 94 ; Parking aid; Removing and installing front park‐
ing aid sender
– Detach connectors of other installed electrical components.

Phaeton 2003 ➤
2.4.2 Installing

– Bolt -4- is to be tightened first.
– Next the two outer bolts of bolt group -2- and then the inner
four.
– Bolt -5- (inserted upwards) in wheel housing and bolt -9- are
to be tightened next.
– The further sequence of bolts and clips is not specified.

Phaeton 2003 ➤
2.5 Front bumper cover add-on parts

⇒ page 153
2 - Bumper strip
❑ Left and right.
❑ Clipped in front bumper
cover
❑ Can only be removed
with front bumper cover
removed
❑ Material PC/ABS
4 - Chrome strip
❑ Left and right.
❑ Clipped in cover section
with cover section re‐
moved
5 - Chrome strip
❑ Clipped in air intake
with air intake removed.
6 - Clip
❑ Qty. 5.
❑ Left and right.
❑ Bolted to front bumper
cover
❑ Additionally clipped in
front bumper cover
8 - Air intake grille
9 - Bolt
❑ 2 Nm
10 - Spoiler cross member
❑ Clipped into spoiler.
11 - Spoiler

Phaeton 2003 ➤
2.6 Front bumper cover substructure parts
1 - Front bumper carrier

2 - Bolt
❑ 20 Nm
⇒ page 10 .
3 - Bolt
❑ 50 Nm
⇒ page 10 .
4 - Hexagon nut
❑ 8 Nm
5 - Bolt
❑ 1 Nm
6 - Bolt
❑ 6 Nm
7 - Bolt
❑ Qty. 3.
❑ 6 Nm
8 - Guide
❑ Left and right.
pull out/push in front
right).
9 - Centre guide
❑ Left and right.
11 - Bolt
❑ 6 Nm
12 - Adjustment element
❑ Qty. 2.
❑ Self-adjusting
❑ Must be screwed out as far as possible before front bumper cover is fitted

Phaeton 2003 ➤
3 Rear bumper cover
3.1 Repairing bumper cover
Note

repaired before renewing bumper. ⇒ General description; Body
maintenance, general body repairs; Work procedures; Plastic re‐
pair procedures
3.2 Tools
3.3 Assembly overview - rear bumper cover
Note
The removal and installation procedures may have to be modified slightly depending on variations in equipment.

Phaeton 2003 ➤
1 - Rear bumper cover

2 - Speed nut
❑ Qty. 10
3 - Bolt
❑ Qty. 10
❑ 1.5 Nm
4 - Spacer sleeves
❑ Qty. 4
5 - Bolt
❑ Qty. 4
❑ 8 Nm
6 - Speed nut
❑ Qty. 2
7 - Bolt
❑ Qty. 4
❑ 8 Nm
8 - Bolt
❑ Qty. 4
❑ 8 Nm
3. Rear bumper cover 159

Phaeton 2003 ➤
3.4 Removing and installing rear bumper

cover
3.4.1 Removing
– Remove luggage compartment side trim ⇒ General body re‐

pairs, interior; Rep. gr. 70 ; Trims; Luggage and load com‐
partment .
– Remove left side battery ⇒ Electrical system; Rep. gr. 27 ;
Battery; Removing and installing second battery on left of lug‐
gage compartment .
– Remove fuse holder ⇒ Electrical system; Rep. gr. 97 ; Re‐
moving and installing fuse holder and relay carrier .
– Remove tail lights ⇒ Electrical system; Rep. gr. 94 ; Lights,
bulbs, switches - exterior; Tail lights .
– Remove bolt -3- from wheel housings.
– Bolt -8- must be removed from brackets from below.
– Remove bolt -7- below tail lights and bolt -5- from inside.

Phaeton 2003 ➤
– Pull rear bumper cover parallel out of guides, with help of a

second mechanic.
Rep. gr. 94 ; Parking aid; Removing and installing rear parking
aid sender
– Separate connectors of other installed electrical components.
3.4.2 Installing

– First, bolt -5- must be tightened from inside.
– Then bolt -7- must be tightened below tail lights
– Bolts -8- and -3- may be tightened in any order.

Phaeton 2003 ➤
3.5 Rear bumper cover add-on parts
1 - Rear bumper cover

❑ Material PC/ABS
❑ Clipped in rear bumper
cover
3 - Bumper strip
cover
❑ Only remove when rear
bumper cover is re‐
moved.
4 - Spoiler
cover
5 - Tail pipe trim
❑ Part of exhaust system
of some engine varia‐
tions.
6 - Clip
❑ Qty. 2
7 - Heat shield
❑ Must be removed before
spoiler can be detached
from rear bumper cover
8 - Pop rivet
❑ Qty. 3
9 - Assembly frame
❑ Must be removed before
spoiler can be detached
from rear bumper cover
10 - Bolt
❑ Qty. 4
11 - Bolt
❑ Qty. 4
12 - Impact absorber
❑ Self-adhesive.

Phaeton 2003 ➤
3.6 Rear bumper cover substructure parts
1 - Bumper carrier
2 - Hexagon nut
❑ Qty. 8
❑ 20 Nm
3 - Securing strip
4 - Bolt
❑ Qty. 9
❑ 2 Nm
5 - Bolt
❑ Qty. 5
❑ 2 Nm
6 - Guide
pull out/push in rear
right)
7 - Expanding nut
❑ Qty. 5
8 - Expanding nut
❑ Qty. 9
❑ Qty. 2
10 - Bolt
❑ Qty. 2
❑ 8 Nm
3.7 Assembly overview - towing bracket
Note
♦ The specified torques refer only to factory-installed towing brackets.

♦ Request torque specifications for other towing brackets from the manufacturers.
♦ Information on electrics can be found under ⇒ Towing mode current flow diagram workshop manual .

Phaeton 2003 ➤
WARNING
Bolts must always be renewed after being loosened.
1 - Towing bracket
2 - Ball coupling
❑ The removable ball
head can be found in a
separate mounting box
in the left luggage com‐
partment bin.
3 - Bolt
❑ Qty. 3 per side
❑ 50 Nm + turn 90° further

Phaeton 2003 ➤
64 – Glazing
1 Flush bonded windows
1.1 Tools

equipment required
♦ Removal kit for flush bon‐
ded windows -
V.A.G 1474 A-
♦ Suction lifter -V.A.G 1344-
♦ Cutting tool -V.A.G 1351-
♦ Windscreen removal kit -
V.A.G 1755-
♦ Cartridge gun -V.A.G 1628-
♦ Cartridge heater -
V.A.G 1939-
1. Flush bonded windows 165

Phaeton 2003 ➤

equipment required
♦ Electric cutter -
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Cutting blade -
V.A.G 1561/8-
♦ Cutting blade -
V.A.G 1561/10-
♦ Cutting blade -
V.A.G 1561/19-
♦ Double cartridge gun -
VAS 5237-
166 Rep. gr.64 - Glazing

Phaeton 2003 ➤
1.2 Materials
♦ 2K glass adhesive DA 004 600 A2 2) 1),3)
♦ 1K glass adhesive DH 009 100 034) 2),5)
♦ Activator D 181 801 A1 1)
♦ Glass primer/paint primer D 009 200 021)
♦ Cleaning solution D 009 401 041)
♦ Primer applicator D 009 500 251)
♦ Adhesive remover D 002 000 10 1)
♦ Cutting cord 357 853 999 A
♦ Mixing nozzle D 000 000 000
1) Materials are stored in box D 004 700.
2) Observe minimum curing period ⇒ page 182 .

3) Double cartridge gun -VAS 5237- must be used to apply these materials.
4) Warm according to manufacturers instructions using cartridge heater -
V.A.G 1939- .
5) Small cartridge, 110 ml, for sealing and/or when a 400 ml cartridge alone is
not sufficient.
1.3 Repairing windscreen
Note
♦ Before renewing windscreen, explore possibilities of repairing

damage to glass.
♦ Damaged windscreens can be repaired with the window repair
kit -VAS 6092- .
♦ This damage must not exceed a certain size or position.
♦ Each window repair kit comes with a set of instructions.

♦ Window repair kit -VAS 6092-
1.4 Assembly overview - windscreen

Phaeton 2003 ➤
1 - Windscreen
❑ Removing windscreen
⇒ page 174
❑ Installing windscreen
⇒ page 175
2 - Dimension a = 2 mm
3 - Sealing lip
❑ If windscreen is to be re-
used, damage to seal‐
ing lip must be avoided.
4 - PUR adhesive sealant
❑ Cross section of bead:
width = 8 mm, height =
10 mm (including resid‐
ual material on window
glass and window
flange).
❑ Use new mixing nozzle
to apply sealant bead.
❑ Minimum curing period
⇒ page 182 .
5 - Windscreen adjuster
❑ 443 845 631 A
6 - Plenum chamber cover
❑ Clipped
❑ The plenum chamber
cover must be pulled off
only by hand
plenum chamber cover
⇒ page 169
7 - Water deflector

Phaeton 2003 ➤
1.5 Removing and installing plenum cham‐

ber cover
1.5.1 Removing
– Remove windscreen wiper arms -1- ⇒ Electrical system; Rep.
gr. 92 ; Windscreen wiper/washer system; Windscreen wiper
system; Removing windscreen washer system
– Undo the four rotary catches -arrows- of the additional cover.
– Lift additional cover and pull it upwards out of clearances to
left and right of cross member.
Note
The plenum chamber cover must not be levered off with a tool (wedge). The windscreen will be damaged and
may subsequently crack.

Phaeton 2003 ➤
– Now pull plenum chamber cover -1-, at right angle, out of

mounting slot on lower edge of windscreen beginning from
edge of windscreen.
– Now pull retaining tabs -2- out from beneath clips -3- and re‐
move plenum chamber cover in direction of windscreen.
1.5.2 Installing
Note
Striking the plenum chamber cover can cause cracks in the wind‐
screen.

Phaeton 2003 ➤
– Spray mounting slot -1- with soap solution to make it easier to

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

centre and moving in direction of arrow.

Phaeton 2003 ➤
– Now secure retaining tabs -2- of plenum chamber cover -1-

with clips -3- on cross member of bulkhead and secure on
bracket on plenum chamber.

Phaeton 2003 ➤
– Hook additional cover -1- with locking lugs -2- in clearances in

cross member of bulkhead.
– Then fasten additional cover in centre and outside using rotary
fasteners -3-.
– Remove wiper arms according to Workshop Manual ⇒ Elec‐
trical system; Rep. gr. 92 ; Windscreen wash/wipe system;
Removing windscreen wiper system .

Phaeton 2003 ➤
1.6 Removing windscreen
– Remove A-pillar trims ⇒ General body repairs, interior; Rep.

gr. 70 ; Trim, insulation; Pillar trims
– Remove left and right sun visors ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Interior equipment; Compartments, covers
and trims .
– Detach moulded headlining only in front area to lower. Re‐
move moulded headlining ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, insulation; Removing and installing moul‐
ded headlining with sliding/tilting sunroof .
– Vehicles with rain sensor ⇒ Vehicle electrics; Electrical sys‐
tem; Rep. gr. 92 ; Window wash and wipe system; Headlight
washer system; Rain and light sensor G397 .
– Now lower moulded headlining (without kinking or damaging
it) sufficiently to allow windscreen to be cut out without damage
occurring to moulded headlining.
– Separate connectors -4- and -5- and secure cables to wind‐
screen using adhesive tape.

Phaeton 2003 ➤
– Then separate connector -1- in plenum chamber and unclip

from retainer -2-. The Kapton cable -3- is also clipped into re‐
tainer -2-.
Note
♦ Make sure that no wiring is damaged when the windscreen is cut out. If wires are damaged, the windscreen
must be renewed.
♦ Ensure that the sealing lip is not damaged when the windscreen is cut out. If the sealing lip is damaged, the
windscreen must be renewed.
– Pull water deflector off retaining strip on A-pillar.

– Release sealing lip from window flange using plastic wedge
and spray with cleaning solution -D 009 401 04- (as substitute
for lubricant).
– Slide protective backing -V.A.G 1474/18- -1- between wind‐
screen and dash panel.
Note
♦ There is a marking on the protective foil. Make sure that the

mark on the protective backing is pushed in as far as the cover
on the dash panel.
♦ If foil is not pushed in far enough, noise insulation can be
damaged.
– Place cutting cord around window.

– Remove sealing lip in upper area of windscreen using plastic
wedge and spray with cleaning solution -D 009 401 04- (as
substitute for lubricant).
– Insert cutting cord into window flange using tube.
– Ensure that cutting cord lies under window in corners.
– Pull end of cutting cord through the adhesive sealing material
into inside of vehicle with awl from removal kit for flush bonded
windows -V.A.G 1474 A- .
– Secure one end of the cord to the reel device -V.A.G 1654- .
– Pull the other end of the thread through into the interior and
pull against with the handle -V.A.G 1351/1- .
– Place reel device -V.A.G 1654- in„Position I“.
– Move reel device according to position required and cut win‐
dow free.
– Press cutting cord against windscreen with a plastic wedge
while cutting.
1.7 Installing windscreen

Preparing used undamaged window for glazing ⇒ page 179
Preparing new window for glazing ⇒ page 180 .
Preparing windscreen with viewing window for chassis number
for vehicles without a chassis number ⇒ page 176
Preparing body flange for glazing ⇒ page 181

Phaeton 2003 ➤

Minimum curing period ⇒ page 182 .
1.8 Preparing windscreen with viewing win‐

dow for chassis number for vehicles
without chassis number
In future all windscreens will be fitted with viewing window for
chassis number.
For vehicles without a chassis number, the viewing window in the
windscreen must be blackened from the inside (primed).
– Clean viewing hole -arrow- of windscreen -1- from inside using
cleaning solution -D 009 401 04- .
– Blacken the viewing window -arrow- from inside using primer
-D 009 200 02- .
– Apply the primer -D 009 200 02- evenly using applicator D 009
500 25 in one stroke on the previously cleaned area of the
windscreen.
– After a drying period of about 10 minutes, prime the viewing
hole a second time.
– The new windscreen can then be fitted ⇒ page 175 .
1.9 Assembly overview - rear window

Phaeton 2003 ➤
1 - Rear window
❑ Removing rear window
⇒ page 178 .
❑ Installing rear window
⇒ page 179 .
2 - Sealing lip
❑ Due to the narrow gap to
edge of roof, damage to
the sealing lip must be
avoided.
3 - PUR adhesive sealant
❑ Cross section of bead:
width = 8 mm, height =
10 mm (including resid‐
ual material on window
glass and window
flange)
❑ Minimum curing period
⇒ page 182 .

Phaeton 2003 ➤
1.10 Removing undamaged rear window
Note
♦ Headliner has been removed for reasons of clarity.

♦ If the glass is to be used again, ensure that electrical connections for window heater and aerial module are
not damaged.
– Remove C-pillar trims and rear shelf ⇒ General body repairs,

interior; Rep. gr. 70 ; Trim, insulation; Pillar trims
– Pull off connectors for heated rear window left and right -ar‐
rows A- and secure on glass using adhesive tape.
– Detach moulded headlining only at rear to lower. Remove
moulded headliner ⇒ General body repairs, interior; Rep. gr.
70 ; Trim, insulation; Roof trims .
– Now lower moulded headlining (without kinking or damaging
it) sufficiently to allow further work to be performed without
damage occurring to moulded headlining.
– Unclip antenna module -1- from rear window -arrows B- and
separate connectors. Set antenna module down on headliner.

Phaeton 2003 ➤
– Separate connectors from antenna module -arrows C-. The

antenna module is glued to the glass with double-sided adhe‐
sive tape. Carefully lever off aerial module from window. Al‐
ways remove damaged adhesive tape.
– Release sealing lip from window flange using plastic wedge
and spray with cleaning solution -D 009 401 04- (as substitute
for lubricant).
– Insert cutting cord into window flange using tube.
– Pull end of cutting cord through the adhesive sealing material
into inside of vehicle with awl from removal kit for flush bonded
windows -V.A.G 1474 A- .
– Pull the other end of the cord through into the interior and
counterhold using handle -V.A.G 1351/1- .
– Secure inner end of cord on reel device.
– Move reel device according to position required and cut win‐
dow free.
– Press cutting cord against window glass with plastic wedge
during cutting process, in order to have clearance at window
flange.
1.11 Installing rear window

Preparing old undamaged window for glazing ⇒ page 179
Preparing new window for glazing ⇒ page 180
Preparing body flange for glazing ⇒ page 181
Minimum curing period ⇒ page 182 .
1.12 Preparing a removed windscreen for

glazing
• When re-using an undamaged window, cut back residual ad‐
hesive sealing material to 1 ... 2 mm just before re-bonding.
• Remaining material serves as adhesion base for newly ap‐
plied adhesive sealing compound.

Phaeton 2003 ➤
– When cutting down adhesive bead -1- with electric cutter -

V.A.G 1561 A- and scraper -V.A.G 1561/8- ensure that heated
window cable -2- and ceramic layer are not damaged.
WARNING
Do not prime bonding surface and do not treat with a cleaning

solution. Keep bonding surface free of dirt and grease.
Exception: if bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐
tivator -D 181 801 A1- .
1.13 Preparing new window for glazing

Only the applied ceramic layer and injection moulded sealing lip
are found on all new windows.
1- Sealing lip
2- Spacing lip
3- Window glass
4- Connection cable for heated window
– Clean a 20 mm wide strip all around edge of window using
cleaning solution -D 009 401 04- .
– Then rub edge of window dry using a lint free cloth.
– Now apply primer -4- evenly in one motion in

-direction of arrow-using applicator -D 009 500 25- -3- to the
previously cleaned area -1- of window.
Ensure that glass adhesive is applied to primed area at a distance
of approx. 2 mm from sealing lip -2-.
• Drying time approx. 10 minutes

Phaeton 2003 ➤
1.14 Preparing body flange for glazing

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

adhesive sealing compound. Keep bonding surfaces free of dirt
and grease.
WARNING
Activator must not have contact with paint or the paintwork will
be damaged.
Exception: if bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐
tivator -D 181 801 A1- .
• If the window flange has been repaired or partially renewed,
the area concerned must be cleaned and primed again after
painting.
Note
It is possible that a laser weld seam lies outside the area of the
adhesive bead. In this case, the exposed weld seam must be
sealed with window adhesive before bonding the window.
– If laser weld seam -3- on panel flange -4- is not covered by

adhesive bead -1-, coat laser weld seam -3- with glass/paint
primer D 009 200 02 -3- and fill laser weld seam with window
adhesive DH 009 100 03 -1-.
1.15 Installation instructions

– The end -1- of the static mixer nozzle has to be shortened by
1 - 2 mm -dimension a-, in order that the adhesive bead di‐
mensions, height = 8 mm and width = 10 mm, can be achieved.
The adhesive bead must be applied at a distance of 2 mm from
sealing lip and to lower edge of window.

Phaeton 2003 ➤
– Apply adhesive all round on the primed area -1- and/or cut-
back adhesive at right angles to the windscreen.
WARNING
Window must be installed within 10 minutes, or adhesive prop‐

erties of glass adhesive will be impaired.
♦ With help of two suction cups -V.A.G 1344- , install glass pane
in window aperture, align to centre and press in onto the spac‐
ing lip.
♦ The gap for the windscreen at the top is 2 mm.
♦ The gap for the rear window at the top and sides is 2 mm.
♦ Secure windscreen during curing period with window adjusters
-443 845 631 A- .
♦ It is absolutely necessary to install the plenum chamber cover
as described on page ⇒ page 169 .
♦ Replace stickers (e.g. for airbag) which may be installed.
♦ Use adhesive tape to secure rear window in position while
curing.
♦ If the adhesive bead is too thick and the adhesive expands
onto the area of the window heating, excess adhesive must
be removed.
1.16 Minimum curing period
WARNING
Special standards must be adhered to when replacing bonded

windows. One of these standards is, for example, that a freshly
bonded windscreen must comply with the safety requirements,
even in an accident, following the minimum prescribed curing
period.
The minimum curing period for the 2K adhesive -DA 004 600 A2-
is three hours for all windows.
Minimum curing period is the time from bonding the window until
vehicle may be used. During this time, the vehicle must stand on
a level surface at room temperature (at least 15 °C).
WARNING
Vehicle is safe to use only after curing period is completed.
1.17 Touching up paint damage

If paintwork is damaged, paint structure must be restored accord‐
ing to specifications in „Paint“ workshop manual.
1.18 Cleaning off excess adhesive sealing

material
– Use adhesive remover -D 002 000 10- as a cleaning solution.
Observe the appropriate safety precautions when performing
this work.

Phaeton 2003 ➤
WARNING
When cleaning freshly installed glass from the inside in the ve‐
hicle, do not press glass outwards.
– First clean painted surface as well as possible using a dry

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

Phaeton 2003 ➤
2 Front door windows
2.1 Assembly overview - front door window
1 - Window channel
❑ Pushed onto flange.
2 - Trim strip
❑ Clipped to window slot
seal.
3 - Cross-head screw
4 - Window slot seal
5 - Trim
6 - Bolt
❑ Qty. 2.
❑ 3.5 Nm
7 - Trim
8 - Insulation
❑ Must be renewed when
door is renewed.
10 - Bolt
❑ 20 Nm
11 - Clamping screw
12 - Cover
⇒ page 187
❑ Window regulator is part
of assembly carrier
❑ Window regulator motor is bolted to assembly carrier from in front.
14 - Bolt
❑ 8 Nm
15 - Loudspeaker
16 - Bolt
17 - Door window
18 - Outer window channel

Phaeton 2003 ➤
2.2 Removing and installing door window
2.2.1 Removing
– Disconnect connectors -1- and -2- for exterior mirror and pull
cable out from the door assembly carrier and the door.
– Carefully lever triangular trim out of fastener and swing out.
– Remove bolts and remove mirror.
– Remove window slot seal ⇒ page 192

Note
2. Front door windows 185

Phaeton 2003 ➤
– Lift rear of door window and swing out of door forwards, in

-direction of arrow-.
2.2.2 Installing
– Insert door window -1- in door. Ensure that door window is
properly located in window channels.
en clamping bolts -2- (Qty. 2) (18 Nm).
al.
2.3 Removing and installing electric window

regulator
2.3.1 Removing
– Secure door window against sliding down with adhesive tape.

Phaeton 2003 ➤
– Remove the three bolts -2-.

– Detach all connectors -3-.
– Remove window regulator motor with control unit -1- from as‐
sembly carrier.
2.3.2 Installing
WARNING
If a new window regulator motor is installed (door control unit),

the additional functions and the excess force limitation feature
have to be coded!

– Tighten bolts to specified torque setting of 3.5 Nm.
– A new window regulator motor is coded using vehicle diagno‐
sis, testing and information system -VAS 5051 A- .
– After coding, allow the window regulator to run upwards once
onto stop in automatic mode and pull switch again for 2 sec‐
onds. This programs the upper stop for the window regulator
motor.
• Check function of window regulator after installation.
2.4 Removing and installing assembly car‐

rier
assembly carrier.
The window regulator is supplied with the assembly carrier.
2.4.1 Removing
– Removing lock cylinder housing ⇒ page 61

Phaeton 2003 ➤

Note

sive tape).
– Disconnect all connections -arrows-.

– Unscrew bolts -2- Specified torque: 20 Nm.

Phaeton 2003 ➤

– Turn assembly carrier and pull connector off door lock.
– Then unclip the clips for electrical cables on back of assembly
carrier.

– Lever door lock with retaining bracket off mounting plate using
a screwdriver.
Note

it from the eye.
2.4.2 Installing

Phaeton 2003 ➤

into spring.
Note

Phaeton 2003 ➤
– Remove loudspeaker -1- before starting bolts for mounting

plate.
– Check that cable bracket -1- is correctly seated on impact bar

-2-.
Note
If cable bracket is not properly clipped to assembly carrier, wiring

harness may be damaged, resulting in failure of all electrical com‐
ponents in door.
en clamping bolts -4- (Qty. 2) to 10 Nm.
al.

Phaeton 2003 ➤
2.5 Removing and installing window slot

seal
2.5.1 Removing
– Removing exterior mirror
– Carefully raise the window slot seal -2- on the B-pillar -arrow a-
using the removal wedge -3409- .
– Carefully pull the window slot seal -2- evenly -arrow b- by hand
away from the door flange on the front door -1-.
2.5.2 Installing
– Press window slot seal equally by hand onto door flange.
2.6 Removing and installing trim
2.6.1 Removing
– Undo the window slot seal as described in the section "Re‐
moving window slot seal" ⇒ page 192 , without removing the
exterior mirror.
– Push window channel -2- far enough to the side to allow you
to reach the bolts. Do not pull window channel out of supports.
– Pull trim plate -1- off the door in -direction of arrow-.
2.6.2 Installing
Note
In the case of window channels with an additional sealing edge,

the existing sealing edge glued onto the trim must be removed.

Phaeton 2003 ➤
– Push trim panel -1- onto the door in -direction of arrow-.

– Retightening bolts -4-.
Specified torque for bolt -4-: 3.5 Nm.
– Check the size of the gap between the doors ⇒ Body Repairs;
Rep. gr. 00 ; Technical data; Body gap dimensions .
Use the setting nut -2- on the trim -1 - to adjust size of the gap.
– Press the window channel -3- into the mounting.

Phaeton 2003 ➤
3 Rear door windows
3.1 Assembly overview - rear door window
1 - Trim strip
❑ Secured with clips to
door flange.
❑ At same time, secures
window guide on door
flange.
2 - Outer window channel
3 - C-pillar trim
5 - Bolt
❑ Qty. 2.
❑ 3.5 Nm
6 - Door
7 - Bolt
❑ 20 Nm
8 - Insulation
10 - Clamping screw
11 - Cover
12 - Bolt
❑ 8 Nm
⇒ page 197
❑ Window regulator is part of assembly carrier
14 - Door window
15 - Window channel trim
16 - B-pillar trim
❑ The adjustment sleeve must be renewed every time trim is adjusted.
17 - Bolt
❑ Qty. 2.
❑ 3.5 Nm
18 - Cross-head screw

Phaeton 2003 ➤
3.2 Removing and installing door window
3.2.1 Removing
– Remove rear door trim, carrier frame and window frame ⇒
General body repairs, interior; Rep. gr. 70 ; Trims, insulation;
Removing and installing door trim .
– Unclip window channel trim from door.
– Unscrew bolts -2- and remove trim from door frame.
– Remove the window slot seal ⇒ page 203

– Lower door window completely.
– Pull off trim strip in front area.
– Pull window guide out of door frame and remove bolts.
– Remove trim.

– Lower door window until clamping bolts -2- for door window
are accessible.
3. Rear door windows 195

Phaeton 2003 ➤
– Swing door window up and out of door.
3.2.2 Installing
– Insert door window in door. Ensure that door window is prop‐
erly located in window channels.
– Press door window into window channel -arrow- and tighten
clamping bolts -2- (Qty. 2) (18 Nm).
al.
3.3 Removing and installing electric window

regulator
3.3.1 Removing
– Secure door window against sliding down with adhesive tape.

Phaeton 2003 ➤
– Remove the three bolts -1-.

– Detach all connectors -3-.
– Remove window regulator motor with control unit -2- from as‐
sembly carrier.
3.3.2 Installing
WARNING
If a new window regulator motor is installed (door control unit),

the additional functions and the excess force limitation feature
have to be coded!

– Tighten bolts to specified torque of 3.5 Nm.
– A new window regulator motor is coded using vehicle diagno‐
sis, testing and information system -VAS 5051 A- .
– After coding, allow the window regulator to run upwards once
onto stop in automatic mode and pull switch again for 2 sec‐
onds. This programs the upper stop for the window regulator
motor.
• Check function of window regulator after installation.
3.4 Removing and installing assembly car‐

rier
assembly carrier.
The window regulator is supplied with the assembly carrier.
3.4.1 Removing
– Remove rear door trim and carrier frame ⇒ General body re‐

Phaeton 2003 ➤

– Pull door handle -2- in direction of arrow and hold. Unscrew
bolt -4- with socket wrench -T 10072- as far as the stop. This
releases the lock cylinder housing.
ing plate.
– Remove bolts -1-.

Phaeton 2003 ➤

sive tape).

– Separate connectors -3- and unclip from assembly carrier.
3.4.2 Installing

Phaeton 2003 ➤

into spring.
Note
Hooking the operating lever in locks the lock. This prevents „in‐
correct“ attachment of the Bowden cable later.

Phaeton 2003 ➤
al.
3.5 Removing and installing window chan‐

nel
3.5.1 Removing
Note
The quarter light is part of window channel.

Phaeton 2003 ➤
– Removing door window ⇒ page 195 .

– Remove subframe ⇒ page 197 .
– Unclip trim strip -1- from window channel.
– Pull window channel -3- out of supports.
– Press window channel including quarter light off door frame in
direction of arrow.
3.5.2 Installing
– Installation is carried out in reverse order of removal.

Phaeton 2003 ➤
3.6 Removing and installing window slot

seal
3.6.1 Removing
– Carefully raise the window slot seal -2- on the B-pillar -arrow a-
using the removal wedge -3409- .
– Carefully pull the window slot seal -2- evenly -arrow b- by hand
away from the door flange on the rear door -1-.
3.6.2 Installing
– Press window slot seal equally by hand onto door flange.
3.7 Removing and installing trim
3.7.1 Removing B-pillar trim

– Remove the window slot seal ⇒ page 203
– Push window channel -3- far enough to the side to allow you
to reach the bolts -4-. Do not pull window channel out of sup‐
ports.
– Pull seal -2- off door flange.
– Pull trim plate -1- off the door in -direction of arrow-.
3.7.2 Installing B-pillar trim
Note
In the case of window channels with an additional sealing edge,

the existing sealing edge glued onto the trim must be removed.

Phaeton 2003 ➤
– Push trim panel -1- onto the door.

– Retightening bolts -5-.
Specified torque for bolt -5-: 3.5 Nm.
– Check the size of the gap between the doors ⇒ Body Repairs;
Rep. gr. 00 ; Technical data; Body gap dimensions .
Use the setting nut -2- on the trim -1 - to adjust size of the gap.
– Press the window channel -4- into the mounting.
– Push seal -3- onto door flange.
3.7.3 Removing C-pillar trim.

Remove the window slot seal ⇒ page 203
– Remove rear door trim, carrier frame and window frame ⇒
General body repairs, interior; Rep. gr. 70 ; Trims, insulation;
Removing and installing door trim .
– Remove trim -1-.
3.7.4 Installing C-pillar trim

– Install in reverse order of removal.
Specified torque for bolt: 3.5 Nm.

Phaeton 2003 ➤
66 – Exterior equipment
1 Removing and installing wheel hous‐
ing liner
1.1 Front wheel housing liner
1 - Wheel housing liner

❑ Removing:
❑ Unbolt wheel ⇒ Run‐
ning gear; Rep. gr. 44 ;
Wheel and tyre installa‐
tion; Wheel installation
❑ Remove bolts -2- (Qty.
24) and pull off wheel
housing liner.
2 - Bolt
❑ Qty. 24.
❑ 1.5 Nm
3 - Cover
❑ For passage to wing/
bumper bolted connec‐
tions.
4 - Speed nut
5 - Expanding nut
1. Removing and installing wheel housing liner 205

Phaeton 2003 ➤
1.2 Rear wheel housing liner
1 - Wheel housing liner

❑ Removing:
❑ Unbolt wheel ⇒ Run‐
ning gear; Rep. gr. 44 ;
Wheel and tyre installa‐
tion; Wheel installation
❑ Remove bolts -2- (Qty.
22) and pull off wheel
housing liner.
2 - Bolt
❑ Qty. 22.
❑ 1.5 Nm
3 - Pop rivet
4 - Heat shield
❑ Riveted to wheel hous‐
ing liner.
5 - Aerodynamic trim
6 - Expanding nut
7 - Speed nut
206 Rep. gr.66 - Exterior equipment

Phaeton 2003 ➤
2 Exterior mirror
2.1 Tools
♦ Removal lever -80-200-
2.2 Assembly overview - rear-view mirror
1 - Mirror mounting
2 - Bolt
❑ Qty. 3
❑ 3 Nm
3 - Insulation
4 - Seal
❑ Self-adhesive.
5 - Cap
6 - Mirror glass
7 - Bolt
❑ Qty. 2
❑ 1 Nm
8 - Assembly part
❑ For turn signal and am‐
bient illumination.
9 - Ambient light
10 - Connector
11 - Side turn signal repeater
12 - Bolt
❑ Qty. 2
❑ 1 Nm
13 - Mirror housing
2. Exterior mirror 207

Phaeton 2003 ➤
❑ Material: ABS.
❑ Depending on equipment, with warning lamp for lane change assist (removing warning lamp for lane
change assist ⇒ page 210 )
14 - Bolt
❑ Qty. 3
❑ 1 Nm
2.3 Removing and installing mirror glass
Note
When doing this repair work, always wear safety goggles and
leather gloves!
2.3.1 Removing
– Protect edge of housing from damage to paintwork e.g. with
fabric-reinforced adhesive tape.
– Press bottom of mirror glass into mirror housing.
– Prise mirror lens -3- out of retainer -2- in the housing with lever
80-200 -arrow 5-.
– Swivel the mirror glass upwards -arrow 6- and detach con‐
nectors -4- on the back of the mirror glass.
2.3.2 Installing
– Connect plug-in contacts to mirror glass.
– Press mirror glass centrally onto bracket in housing.
– Mirror glass engages audibly.
2.4 Removing and installing mirror housing
2.4.1 Removing
– Remove mirror glass ⇒ page 208 .
– Fold rear-view mirror forwards to ease removal and installa‐
tion.

Phaeton 2003 ➤
– Remove three bolts -1-.

– Detach connector of warning lamp for lane change assist, if
the latter is installed.
– Pull mirror housing -3- upwards off mirror mounting -2-.
2.4.2 Installing
2.5 Removing and installing side turn signal

repeaters
Note
♦ The side turn signal repeaters are fitted with long-life light-
emitting diodes (LEDs) instead of conventional bulbs.
♦ Therefore, changing bulbs is not necessary. In case of dam‐
age, the entire turn signal must be renewed.
2.5.1 Removing
– To remove side turn signal, mirror glass and mirror housing
must be removed, see from ⇒ page 208 .
– Assembly bracket -2- with side turn signal is located on back
of mirror base plate.
– Remove the two bolts -1-.
– Release connectors -3- and pull off.
– Release two locking hooks -1- on front of mirror base plate in

-direction of arrows-.
– Remove side turn signal forwards.

Phaeton 2003 ➤
2.5.2 Installing
2.6 Removing and installing entry light
2.6.1 Removing
– To remove ambient illumination, mirror glass and mirror hous‐
ing must be removed, see from ⇒ page 209 .
– Release and disconnect connection -1- on the back of mirror
base -2-.
– Detach connector for turn light.
– Remove the two screws -1- from the front of the mirror base.
– Remove assembly part -2- downwards from the mirror base
-arrow-.
– Carefully press ambient illumination -2- out of the latches in

assembly part -1-.
– To change a bulb, disconnect connection -3- from ambient il‐
lumination -2-.
2.6.2 Installing
2.7 Removing and installing warning lamp

for lane change assist
2.7.1 Removing
– Remove mirror housing ⇒ page 208 .

Phaeton 2003 ➤
– Release locking hooks for warning lamp for lane change assist
in mirror glass housing -arrow a-.
– Push warning lamp for lane change assist out of mirror hous‐
ing in -direction of arrow b-.
2.7.2 Installing
2.8 Assembly overview - rear-view mirror
1 - Exterior mirror
❑ With attachments.
❑ Material: ABS.
2 - Seal
❑ Self-adhesive.
3 - Insulation
4 - Carrier frame
5 - Cover for exterior rear-view
mirror
6 - Bolt
❑ Qty. 3
❑ 3 Nm
7 - Connector

Phaeton 2003 ➤
2.9 Removing and installing rear-view mir‐

ror
2.9.1 Removing
pairs, interior; Rep. gr. 70 ; Trim, insulation; Door trims .
– Disconnect connectors -1- and -2- for exterior mirror and pull
cable out from the door assembly carrier and the door.
– Carefully lever cover for exterior rear-view mirror out of locking

mechanism -1- and swing out of retainer -2-.
– Remove bolts -arrow- and remove mirror.
2.9.2 Installing
2.10 Removing and installing cap
2.10.1 Removing
– Remove exterior rear-view mirror ⇒ page 212 .
– Pull out insulation -2- from mirror base plate -1-.

Phaeton 2003 ➤
– Using an appropriate screwdriver, release locking lugs -3- of

cap -4- and take cap out of opening.
2.10.2 Installing

Phaeton 2003 ➤
3 Radiator grille of vehicles up to

05.2010
3.1 Assembly overview - radiator grille
1 - Radiator grille
❑ Material: ASA
3 - Bolt
❑ Qty. 5.
❑ 2 Nm
4 - Bolt
❑ Qty. 4.
❑ 4.5 Nm
5 - Company emblem
❑ Clipped into radiator
grille
3.2 Removing and installing radiator grille
3.2.1 Removing
– Undo all 9 bolts.

Phaeton 2003 ➤
– Swing lower part of grille forwards slightly -arrow 1-.

– Then pull radiator grille downwards -arrow 2- out of retaining
brackets.
3.2.2 Installing
– Guide radiator grille with retaining brackets from below
-arrow 1- into bonnet.
– Swing down lower part of grille -arrow 2- and centre it.
– First insert upper bolts and then bolts at sides.
3. Radiator grille of vehicles up to 05.2010 215

Phaeton 2003 ➤
4 Radiator grille of vehicles from

06.2010
4.1 Assembly overview - radiator grille
Note
The radiator grille is supplied as a complete spare part, except for items -5-, -11- and -12-. However, the items
indicated can be replaced individually.
1 - Bolt
❑ Qty. 6.
❑ 1 Nm
❑ For securing cover part
-2- to radiator grille -4-
❑ Bolted onto radiator
grille -4- with bolts -1-.
3 - Bolt
❑ Qty. 3.
❑ 1 Nm
❑ For securing insert -11-
to radiator grille -4-
4 - Radiator grille
5 - Honeycomb grille
grille -4-
❑ Only fitted on vehicles
without adaptive cruise
control
6 - Trim strip on cover
❑ Left and right.
grille -4-
7 - Top trim strip
❑ Left and right.
grille -4-
8 - Centre trim strip
❑ Left and right.
❑ Clipped into radiator grille -4-
9 - Lower trim strip
❑ Left and right.
10 - Decorative trim
11 - Insert
❑ Bolted onto radiator grille -4- with bolts -3-.

Phaeton 2003 ➤
❑ Also clipped into radiator grille -4-
12 - Company emblem
❑ Clipped into insert -11-
❑ Different versions, assignment ⇒ Parts catalogue „ETKA“
❑ Removing and installing on vehicles without adaptive cruise control ⇒ page 219
❑ Removing and installing on vehicles with adaptive cruise control ⇒ page 222
4.2 Removing and installing radiator grille
4.2.1 Removing
– Remove bolts -3- and -4-.

– Tip upper part of radiator grille -1- forwards a little away from
the lock carrier.
– The pull radiator grille -1- upwards out of latches -arrow- of
front bumper cover -2-.
4. Radiator grille of vehicles from 06.2010 217

Phaeton 2003 ➤
4.2.2 Installing
– Insert radiator grille -1- into latches -arrow- of front bumper

cover -2- from above until they latch in place audibly.
– Tip upper part of radiator grille -1- towards the lock carrier.
– Screw in bolts -3- and -4-.

Phaeton 2003 ➤
4.3 Removing and installing VW emblem on

vehicles without adaptive cruise control
4.3.1 Removing
– Undo bolts -3- on rear of radiator grille -2-.

– Release locking hooks -arrows- and pull insert with VW em‐
blem -1- forwards out of radiator grille -2-.

Phaeton 2003 ➤
– Release locking hooks -3- on VW emblem -1-.

– Turn VW emblem -1- in -direction of arrow-.
– Remove VW emblem together with locking hooks -3- through
the recesses -4- in the insert -2-.
4.3.2 Installing
– Push VW emblem -1- together with locking hooks -3- into the
insert -2- from the front.
– Turn VW emblem -1- in -direction of arrow- until the locking
hooks -3- latch into place in the insert -2-.

Phaeton 2003 ➤
– Push insert together with VW emblem -1- into the radiator grille
-2- from the front until the locking hooks -arrows- latch into
place.
– Screw in bolts -3- on rear of radiator grille -2-.

Phaeton 2003 ➤
4.4 Removing and installing VW emblem on

vehicles with adaptive cruise control
4.4.1 Removing
– Undo bolts -3- on rear of radiator grille -2-.

– Release locking hooks -arrows- and pull insert with VW em‐
blem -1- forwards out of radiator grille -2-.

Phaeton 2003 ➤
– Release locking hooks -arrows a- on VW emblem -1- and tip

VW emblem forwards a little.
– Remove VW emblem together with retaining lugs -1- upwards
out of the insert -2- -arrows b-.
4.4.2 Installing
– Place VW emblem -1- together with retaining lugs -arrow a-
into the insert -2-.
– Tip top of VW emblem -1- towards the insert -2- -arrow b- until
the locking hooks on the VW emblem latch into place.

Phaeton 2003 ➤
– Push insert together with VW emblem -1- into the radiator grille
-2- from the front until the locking hooks -arrows- latch into
place.
– Screw in bolts -3- on rear of radiator grille -2-.

Phaeton 2003 ➤
5 Roof mouldings
5.1 Assembly overview - roof strip
1 - Roof moulding
❑ Remove water deflector
⇒ page 228 .
❑ Removing; starting at
windscreen, lever off
with soft plastic wedge.
❑ Do not bend roof mould‐
ing
❑ Installing; place roof
moulding on end of rear
roof channel and press
in from rear to front up to
stop.
2 - Bolt
❑ 9 Nm
3 - Fastening element
❑ For roof rack.
4 - Roof channel
5 - Securing clips
⇒ page 226
5. Roof mouldings 225

Phaeton 2003 ➤
5.2 Removing and installing securing clips

for roof moulding
5.2.1 Removing
♦ Push white and black parts of clip against each other as shown
in illustration. Protect painted surfaces from damage.
5.2.2 Installing
♦ Push white and black parts of clip against each other as shown
in illustration. Protect painted surfaces from damage.
5.3 Assembly overview - drip channel

Phaeton 2003 ➤
1 - Drip channel
2 - Centring hole
❑ When installing, insert
first pop rivet here.
❑ Align drop deflector
along roof side mem‐
bers.
3 - Roof side members
4 - Pop rivet
❑ Qty. 25.
5 - Cover strip
❑ Strip must be levered
out using plastic wedge
on outer side beginning
at C-pillar.
❑ When installing, insert
inside edge first.
6 - Centring cut-out
❑ This cut-out aligns cover
strip on water deflector.
5. Roof mouldings 227

Phaeton 2003 ➤
5.4 Assembly overview - water deflector
1 - Water deflector
❑ Lift deflector by hand out
of clips beginning at
bonnet and then pull out
of roof moulding.
2 - Pop rivet
❑ 2 per retaining clip.
3 - Retaining clip
❑ Retaining clip can be re‐
newed only after wind‐
screen has been re‐
moved.
4 - A-pillar
5 - Roof moulding
6 - Sealing lip
❑ After installing mould‐
ing, press lip behind
windscreen.

Phaeton 2003 ➤
6 Protective strips
6.1 Assembly overview - protective moulding
1 - Protective strip on wing

❑ Material PP/EPDM.
❑ Aluminium insert.
⇒ page 231 .
2 - Bolt
❑ Qty. 2 on each protec‐
tive moulding
❑ 2 Nm
3 - Front door protective
moulding
❑ Self-adhesive.
❑ Material: Aluminium
❑ Insert: PP/EPDM.
4 - Rear door protective mould‐
ing
❑ Self-adhesive.
❑ Material: Aluminium
❑ Insert: PP/EPDM.
5 - Protective side panel
moulding
❑ Aluminium insert.
⇒ page 231 .
6 - Centring lug
❑ Determines position of
trim strip.
7 - Seal
❑ Self-adhesive.
8 - Insert for trim strip
9 - Insert for trim strip
6. Protective strips 229

Phaeton 2003 ➤
6.2 Renewing protective side strips
– Undo bolts -2- on front and rear ends of sill panel trims.
– Before removing, warm trim strips with hot air blower and pull
off.
– Clean exterior panels with naphtha, treat with silicone remover
and then rub dry.
– Pull protective backing off trim strips -3- and -4- before attach‐
ing. Position the trim strips and press on firmly. Working tem‐
perature about 20 °C.
– Specified torque for bolts: 2 Nm.

Phaeton 2003 ➤
6.3 Assembly overview - trim strips on wing

and side panel
– After being painted, trim strip -1- must be assembled.
– Clips -2- can be moved and serve to align trim strip -1- with
front door trim strip -7-.
– After aligning strip, pull tab -8- on adhesive tape -9- and press
trim strip onto body panel.
– Chrome insert -3- is aligned with trim strip via guides -5- and
-6- and is secured by pressing on with adhesive strip -4-.
– After being painted, trim strip -1- must be assembled.

– Clips -2- can be moved and serve to align trim strip -1- with
rear door trim strip -3-.
– After aligning strip, pull tab -8- on adhesive tape -9- and press
trim strip onto body panel.
– Chrome insert -5- is aligned with trim strip via guides -4- and
-7- and is secured by pressing on with adhesive strip -6-.
6.4 Renewing trim strip insert

The trim strip aluminium profile -1- on the doors is joined to the
body panel -2- by its self-adhering surface -4-.
After being painted, the plastic profile is bonded to the aluminium
profile by the adhesive surface -5-.
Note
The plastic profile cannot be removed without destroying it.
6. Protective strips 231

Phaeton 2003 ➤
6.5 Assembly overview - cover strips
Note
Before installing, examine all fastening parts for damage and renew as necessary.
1 - Front door trim panel

❑ Before bolting on, align
with smallest possible
gap to door edge.
2 - Clip
3 - Hexagon nut
❑ Part of cover strip.
4 - Rear door trim panel
❑ Before bolting on, align
with smallest possible
gap to door edge.
5 - Bolt
❑ 1.5 Nm
6 - Front door
7 - Rear door

Phaeton 2003 ➤
7 Sill trim
7.1 Assembly overview - sill protective strip
1 - Front protective strip

❑ Align to stop on wing.
2 - Grommet
3 - Clip
4 - Rear protective strip
❑ Align to stop on side
panel.
7. Sill trim 233

Phaeton 2003 ➤
7.2 Assembly overview - sill panel mouldings
1 - Front sill panel moulding

❑ Self-adhesive.
2 - Rear sill panel moulding
❑ Self-adhesive.
3 - Centring lug
❑ Determines position of
sill panel moulding

Phaeton 2003 ➤
7.3 Renewing sill panel moulding
– Before removing, warm sill panel trim with hot air blower and
pull off.
– Clean exterior panels with naphtha, treat with silicone remover
and then rub dry.
– Pull protective backing off sill panel moulding -1- and -2- be‐
fore attaching. Attach sill panel trim lightly and then press
forcefully on. Working temperature about 20 °C.
7. Sill trim 235

Phaeton 2003 ➤
8 Lettering
8.1 Tools
♦ Hot air blower -V.A.G 1416-
8.2 Installation instructions for lettering and

emblems
Note
♦ Before removal, warm the lettering with a hot air blower -V.A.G
1416- .
♦ Adhesive remover -D 002 000 10- must be used exclusively.
♦ Ensure that bonding surfaces are free of dust and grease.
♦ The lettering must be bonded in place immediately after clean‐
ing.
Working temperature approx. 21 °C.
8.3 Rear lettering - dimensions

Phaeton 2003 ➤
❑ From outer edge of rear
lid to lettering.
2 - Dimension b = 38 mm
❑ From lower edge of rear
lid to upper edge of let‐
tering.
3 - Dimension c = 75 mm
❑ From lower edge of rear
lid to lower edge of let‐
tering.
4 - Dimension d = centre line
Centre line through rear lid,
centre line through logo, centre
of lettering.
8. Lettering 237
Phaeton 2003 ➤
8.4 Dimensions of Volkswagen R GmbH

emblem
8.4.1 Dimensions of Volkswagen R GmbH emblem, left wing
❑ Transfer -dimension a -
from lower edge of wing
to wing.
❑ Use -dimension b- to
check the distance from
the upper edge of the
emblem to the edge of
the wing.
❑ Use -dimension c- to
the lower edge of the
the wing.

Phaeton 2003 ➤
8.4.2 Dimensions of Volkswagen R GmbH emblem, right wing
❑ Transfer -dimension a -
from lower edge of wing
to wing.
❑ Use -dimension b- to
the upper edge of the
the wing.
❑ Use -dimension c- to
the lower edge of the
the wing.
8. Lettering 239

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Service

Service Department. Technical Information

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 54

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.13 Removing and installing door outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1 Front bumper cover of vehicles up to 05.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3 Rear door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Special tools and workshop

1.2 Fitting locations of adaptive cruise con‐

1.2.1 ACC sender on right -G259- / ACC

The ACC sender on right -G259- is described; the description for

Location: on back of cross member.

1.2.2 ACC sensor -G550-

1.3 Assembly overview - lock carrier, service position

2 Rep. gr.50 - Body - front

1.4 Service position

1.4.1 Moving to service position

– Remove front bumper cover of vehicles up to 05.2010

4 Rep. gr.50 - Body - front

– The lock carrier -1- can be pulled forwards about 10 cm on the

1.4.2 Moving from service position

– Align lock carrier on longitudinal members and between wings

– In vehicles with ACC, observe installation instructions for the

1.5 Assembly overview - lock carrier with attachments

1 - Lock carrier with add-on

1.6 Removing and installing lock carrier with

♦ Because the lock carrier is a safety-relevant component, it

6 Rep. gr.50 - Body - front

– Remove front bumper cover of vehicles up to 05.2010

♦ Do not hang condenser and hydraulic oil cooler from lines.

– Align lock carrier to longitudinal members and between wings

8 Rep. gr.50 - Body - front

During assembly, ensure that all connectors and hose connec‐

1.7 Assembly overview - lock carrier attaching parts

1.8 Installation instructions for longitudinal

1.9 Installation instructions for vehicles with

1.9.1 Installation instructions for ACC sender

The ACC sender on right -G259- is described; the description for

10 Rep. gr.50 - Body - front

The ACC sender on right -G259- must be adjusted after:

1.9.2 Installation instructions for the ACC sen‐

1.10 Removing and installing ACC senders

1.10.1 Removing and installing ACC sender on

The ACC sender on right -G259- is described; the description for

1.10.2 Removing and installing ACC sensor -

12 Rep. gr.50 - Body - front

2.2 Assembly overview - front wing

Only the left side is shown. The right side is similar.

14 Rep. gr.50 - Body - front

2.3 Removing and installing front wing

– Remove front bumper cover of vehicles up to 05.2010

Before bolting on wing, apply a zinc intermediate layer -AKL 381

16 Rep. gr.50 - Body - front

2.4 Front wing - bolting sequence

♦ Only the left side is shown. The right side is similar.

– The sequence in which the nuts and bolts 1 - 23 are tightened

3.2 Assembly overview - noise insulation in vehicles up to 05.2010

1 - Front noise insulation

18 Rep. gr.50 - Body - front

3.3 Assembly overview - noise insulation in vehicles up to 06.2010

1 - Front noise insulation

55 – Bonnet, rear lid