POLO
Removing
With the ignition off, disconnect the ground wire from the battery (-).
Attention: Follow the instructions given in chapter «Removing and installing the battery».
Remove rear door trim see relevant chapter below.
Disconnect the connectors for the heating and rear window cleaning systems, as well as the additional brake signal and the central locking system. Disconnect the washer fluid hose from the rear window washer nozzle.
Note: To facilitate subsequent installation, tie a cord to the ends of the wires, which, after pulling out the wires, must remain in the rear door.
To facilitate reassembly, mark the installation position of the hinges -13- in relation to the rear door with a felt-tip pen, see figure N55-0268.
On each side of the door, loosen, but do not unscrew, the 2 hinge bolts -12-, see drawing N55-0268.
Safety note
Before releasing the spring-gas stop, ask an assistant to support the door. Otherwise, the door will fall down, because. one stop will not be able to hold it.
Use a small screwdriver -3- to slightly depress the retaining clip -1- and remove the spring-gas stop -2- from the upper spherical pin. Remove the second spring-gas stop in the same way.
Unscrew bolts -12- and, together with an assistant, remove rear door -1- and carefully set aside, see figure N55-0268.
Installation
Together with an assistant, attach the rear door to the hinges. Align the used rear door according to the marks made before removal.
Tighten bolts -12- on left and right by hand. see drawing N55-0268.
Put the spring-gas stop on the spherical pin and fix it. Install the second spring-gas stop in the same way.
Check the gaps in the joints of the rear door. The tailgate is correctly adjusted when the gap is even on all sides in the closed position and does not protrude too far in or out, and its contours match the adjacent parts.
Prescribed joint clearances/POLO:
- Tailgate - Rear Body Sides/Roof 4.5+1,0 mm
- Tailgate - tail light 3.0+1,0 mm
- Tailgate - Bumper Cover 4.0+1,0 mm
If the specified values are not observed, unscrew the fastening of the locking clip -7- and align it by moving the rear door to the left and right. If necessary, loosen nuts -11- at the body, see figure N55-0268.
After alignment, tighten the hinge bolts to 10 Nm and the nuts to 24 Nm.
Tighten the locking bracket to 22 Nm.
Pull the washer fluid hose, as well as the electrical wires, with a cord, and route them accordingly in the new door.
Install rear door trim see relevant chapter below.
Connect ground wire to battery (-).
Attention: Follow the instructions given in chapter «Removing and installing the battery».
Adjustment
Attention: When adjusting the car must be on wheels.
Open the tailgate, use a 24 mm ring spanner to turn the adjusting buffer 90°counterclockwise -arrow- and remove it from the profiled hole.
Using a 3 mm hexagon wrench, loosen the locking bolt just enough to remove the locking slider. 1 - rubber cap.
Remove the latch slider from the housing and adjust to the dimension a = 12.5 mm.
Note: The new buffer is already pre-set to 12.5mm.
Insert the adjusting buffer, turn it 90°clockwise and thus fix it in the profiled hole.
On the left and right sides, above the rear light, unscrew the cap -1- from the blind rivet nut -2-.
Close the back door, but do not lock it with a lock.
Set the gap in the joint between the rear door and the side of the body equal to 4.5 mm.
At the service station, a VW-3371 gap adjuster is used for this.
Open the back door again.
Note: The tailgate is now adjusted with a preload of approximately 3 mm.
On the left and right sides, above the rear light, screw the cap into the blind rivet nut.
Using a hexagon wrench, screw in locking bolt -1- no more than a = 25 mm.
Close the rear door and check the correct gaps in the joints.
Only IBIZA
Removal and installation of the rear door, as well as its adjustment for the IBIZA model are carried out, in principle, in the same way as for the POLO.
The rear door is attached to each hinge with two nuts. The tightening torque of the nuts during installation is 22 Nm.
Specified joint clearances/IBIZA:
- Tailgate - Rear Body Sides 3 to 4mm
- Tailgate - 3.5mm bumper shroud
POLO Limousine boot lid only
Prescribed joint clearances/POLO for Limousine models:
- Trunk Lid - Rear Side Body Parts 3.0+1 mm
- Trunk Lid - Bumper Cover 4.5+1 mm
Screw in locking bolt -1- no more than a = 16 mm, see figure N55-0212.
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