Phaeton Body Manual

Phaeton Body Manual

Student Reference

Volkswagen of America, Inc. Service Training Printed in U.S.A. Printed 08/2003 ©2003 Volkswagen of America, Inc. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. All requests for permission to copy and redistribute information should be referred to Volkswagen of America, Inc. Always check Technical Bulletins and the Volkswagen Worldwide Repair Information System for information that may supersede any information included in this booklet. Trademarks: All brand names and product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners.

Table of Contents Specifications ................................................................................................ 1 Front Bumper and Fenders .......................................................................... 2 Front Bumper Support ................................................................................. 3 Rear Bumper .................................................................................................. 4 Hood ............................................................................................................... 5 Front Doors .................................................................................................... 6 Rear Doors ..................................................................................................... 8 Luggage Compartment Lid ........................................................................ 10 Exterior Lights ............................................................................................. 14 Mirrors .......................................................................................................... 15 Glass ............................................................................................................. 16 Exterior Trim ................................................................................................ 18 Sunroof ........................................................................................................ 20 Instrument Panel ......................................................................................... 21 Console ........................................................................................................ 23 Interior Trim ................................................................................................. 26 Luggage Compartment Trim ...................................................................... 28 Front Seats .................................................................................................. 31 Rear Seats .................................................................................................... 32

New!

Vehicle Identification Number Plate .......................................................... 33 Bonded Joints ............................................................................................. 34 Body Insulation ........................................................................................... 35 Body Cavity Sealing .................................................................................... 39 Body Repair ................................................................................................. 40 Special Tools ................................................................................................ 45

Important/Note! The Service Training Student Reference provides you with information regarding designs and functions. The Service Training Student Reference is not a Repair Manual! For maintenance and repair work, always refer to the current technical literature

i

Specifications Specifications

57.09 in (1450 mm)

64.09 in (1628 mm)

63.46 in (1612 mm)

74.92 in (1903 mm)

44.13 in (1121 mm)

113.43 in (2881 mm) 199.02 in (5055 mm)

41.38 in (1051 mm) SSP270/118

• Length 199.02 inches (5055 mm)

• Rear track width 63.46 inches (1612 mm)

• Width 74.92 inches (1903 mm)

• Permitted gross vehicle weight 5732 – 6592 pounds (2600 – 2990 kg) (depending on the engine)

• Height 57.09 inches (1450 mm) • Wheelbase 113.43 inches (2881 mm)

• Curb weight 4398 – 5320 pounds (1995 – 2413 kg) (depending on the engine)

• Turning circle 39.4 feet (12 m)

• Luggage compartment space 17.7 cubic feet (500 liters)

• Fuel tank capacity 23.8 gallons (90 liters)

• Drag coefficient 0.32 CD

• Front track width 64.09 inches (1628 mm)

1

Front Bumper and Fenders

The front bumper components are plastic.

The spoilers and chrome trim strips are attached with clips and can be replaced separately.

VOA889-003a

The front bumper and fenders are attached with screws from the inside.

The front fenders are plastic.

Special Fasteners

VOA889-003b

2

Front Fenders – Repair Group 50 Bumpers – Repair Group 63

Front Bumper Support

VOA889-004a

The Right Distance Regulation Sensor G259 is attached to the front right bumper deformation element on Phaetons equipped with the Adaptive Cruise Control feature.

VOA889-004b

The sensor cover must only be painted with millimeter-wave permeable color. It must not be recoated on the inside or the outside, and must not be covered.

An additional support is installed between the longitudinal frame members just behind the front bumper components.

Metal Plastic VOA889-004c

Bumpers – Repair Group 63

3

Rear Bumper

The rear bumper components are plastic.

VOA889-010a

Trailer hitch options may vary depending upon marketing area.

The chrome trim covers for the exhaust system are attached to the rear bumper. Metal Plastic VOA889-010b

4

Bumpers – Repair Group 63

Hood

Hood height can be adjusted using the stop screws at the hinges.

The hood is aluminum.

VOA889-005

Hood – Repair Group 55

5

Front Doors

Door seals are self-adhesive. The door seals cannot be removed without damage. If removed, they must be replaced.

Newly developed window guides ensure smooth operation and reduce wind noise.

The front doors are aluminum. Laser-welded aluminum die castings and extruded sections provide four times the rigidity of a conventional design.

Metal Rubber

VOA889-006

6

Front Doors – Repair Group 57

Front Doors Basic front door design is similar to other Volkswagen models.

VOA889-007

Front Doors – Repair Group 57

7

Rear Doors

Door seals are self-adhesive. The door seals cannot be removed without damage. If removed, they must be replaced.

Newly developed window guides ensure smooth operation and reduce wind noise.

The rear doors are aluminum. Laser-welded aluminum die castings and extruded sections provide four times the rigidity of a conventional design.

Metal Rubber

VOA889-008

8

Rear Doors – Repair Group 58

Rear Doors

Basic rear door design is similar to other Volkswagen models.

VOA889-009

Rear Doors – Repair Group 58

9

Luggage Compartment Lid The standard luggage compartment lid is opened and closed manually with an electrical assist.

Emergency opening is achieved mechanically with the key inserted in the lock mechanism in the VW emblem on the lid.

10

Lids – Repair Group 55

Luggage Compartment Lid

Metal

VOA889-024

Lids – Repair Group 55

11

Luggage Compartment Lid To open the power-assisted luggage compartment lid, operate either the switch on the door panel, the microswitch in the VW emblem on the lid, or the radio remote control. Emergency opening is achieved mechanically with the key inserted in the lock mechanism in the VW emblem on the lid.

The Rear Lid Lock Button (in Luggage Compartment) E406 in the luggage compartment lid is used to close the lid.

12

Lids – Repair Group 55

Luggage Compartment Lid

The power-assisted luggage compartment lid is opened and closed by an electro-hydraulic mechanism.

Metal Aluminum

VOA889-025

Lids – Repair Group 55

13

Exterior Lights

All front lighting elements except fog lights are integrated into the front headlight housings.

Standard lighting includes xenon headlights with gas discharge low-beam lamps and HB 3 high-beam lamps.

Front fog lights are mounted in the bumper. They use H11 lamps behind transparent lenses.

The rear seats must be removed to replace the center high-mounted brake light.

Rear light elements are LEDs, except for the backup lights which use a replaceable HPL bulb.

Rear light assemblies are alignment adjustable. VOA889-026

14

Exterior Lights – Repair Group 94

Mirrors

The inside rearview mirror is attached to a mounting plate on the windshield.

Special Fastener Glass

The outside rearview mirrors feature power adjustment, power fold, automatic dimming, side turn signal lights, and surround lighting. The outside mirror housing, turn signals, and surround lighting components can all be replaced separately. VOA889-011

Exterior Mirrors – Repair Group 66 Interior Mirrors – Repair Group 68

15

Glass The Phaeton windshield is not precoated. New windshields must be pretreated in accordance with Repair Manual instructions before installation. Rain/Light Recognition Sensor G397 is installed at the top center of the windshield.

The rubber seal bonded to the windshield can be replaced separately.

Glass Rubber

VOA889-012

16

Glass – Repair Group 64

Glass The rear window is not precoated. New rear windows must be pretreated in accordance with Repair Manual instructions before installation.

Tungsten heating elements and all antennas are integrated into the rear window.

The rubber seals bonded to the rear window can be replaced separately.

Glass Rubber

VOA889-013

Glass – Repair Group 64

17

Exterior Trim

The plastic clips that retain the roof trim strips are wedged into the roof joint.

The metal roof rack mounts are fastened to the roof joint channel with screws.

Plastic Metal Aluminum

VOA889-014

18

Exterior Trim – Repair Group 66

Exterior Trim

The rain channel moldings at the A-pillars are attached with riveted retaining clips.

Metal Glass Rubber Aluminum

VOA889-015

Exterior Trim – Repair Group 66

19

Sunroof

A tilt and slide sunroof is available on the Phaeton. The wind deflector is controlled electro-mechanically to reduce wind noise and drafts, depending on the driving speed and the amount the sunroof is open. The sunshade moves at the same time that the sunroof glass is opened or closed, but it can also be separately controlled electrically regardless of the position of the glass.

Plastic Glass

VOA889-020

20

Sunroof – Repair Group 60

Instrument Panel The instrument panel top covers and panels can be replaced separately. The front parking aid displays in the defroster panel are a new feature.

Wood trim elements are replaceable separately.

VOA889-016

Interior Trim – Repair Group 70

21

Instrument Panel The multi-part instrument panel is attached to an aluminum carrier that also acts as an air duct.

Instrument panel alignment to door trim panels is optimized by the use of special shims.

Special Parts

VOA889-017

22

Interior Trim – Repair Group 70

Console Four-seat Phaetons have full-length center consoles.

Full-length center consoles include front and rear seat center armrests, cupholders, phone and miscellaneous storage, rear air vents, rear seat controls, and rear AC controls.

VOA889-030

Interior Trim – Repair Group 70

23

Console

VOA889-031

24

Interior Trim – Repair Group 70

Console

Five-seat Phaetons have short center consoles.

Short center consoles include front seat center armrests, cupholders, phone and miscellaneous storage, and rear air vents.

VOA889-032

Interior Trim – Repair Group 70

25

Interior Trim

The interior trim panels are fastened with a combination of clips and screws.

The sides of the rear shelf trim panel are connected to the bottom edges of the C-pillar trim panels.

Plastic

VOA889-018

26

Interior Trim – Repair Group 70

Interior Trim

The roof insulation and reinforcements are bonded. The headliner is held in place by the pillar trim panels.

The carpeting provides noise insulation and is comprised of three separate sections. The insulation panel forward of the instrument panel is installed flush with the bottom of the windshield.

If this insulation panel is damaged during windshield replacement, it must also be replaced.

Plastic Metal

VOA889-019

Interior Trim – Repair Group 70

27

Luggage Compartment Trim

The luggage compartment trim panels are fastened with a combination of clips and screws.

Plastic Metal

VOA889-021

28

Interior Trim – Repair Group 70

Luggage Compartment Trim

VOA889-022

Interior Trim – Repair Group 70

29

Luggage Compartment Trim

Several control modules are installed on the insulation panel under the rear shelf.

There is an additional trim panel in the luggage compartment behind the rear seatback.

Plastic

VOA889-023

30

Interior Trim – Repair Group 70

Front Seats Front seats are new designs and are available in 12-way and 18-way adjustable versions.

Different front seat variants have different comfort features depending upon their configuration and optional equipment. The optional automatic lap belt must be separated from the 18-position front seats in order to remove these seats.

All front seats on the Phaeton are equipped with an active headrest system.

VOA889-028

Seat Frames – Repair Group 72 Seat Upholstery, Covers – Repair Group 74

31

Rear Seats

The Phaeton is available with a standard or premium full-width rear bench seat, or 10-position individual rear seats with a center console between them. Different rear seat variants have different comfort features depending upon their configuration and optional equipment.

VOA889-029

32

Seat Frames – Repair Group 72 Seat Upholstery, Covers – Repair Group 74

Vehicle Identification Number Plate In addition to the VIN located on the front left edge of the instrument panel that is visible through the windshield, the vehicle identification number is stamped in the upper support for the right front fender. The model designation is 3D. 3

D

Special Parts

PR lables are attached to the body in the luggage compartment just forward of the spare wheel recess.

VOA889-027

General – Repair Group 00

33

Bonded Joints

In addition to welding, high-stress areas of the body are reinforced with an epoxy resin bond to ensure rigidity. Epoxy Adhesive

VOA889-037

34

Body Insulation Body insulation is used to reduce noise levels in the Phaeton.

Some body insulation is installed during body shell assembly

Special Parts VOA889-033

35

Body Insulation

Special Parts

VOA889-034

36

Body Insulation

Some body insulation is applied during final body assembly stages.

Special Parts

VOA889-035

37

Body Insulation

Special Parts

VOA889-036

38

Body Cavity Sealing

Special Body Cavity Sealing Areas

VOA889-038

39

Body Repair The Phaeton main body structure consists of high-grade and super high-strength steels and is completely galvanized for corrosion protection.

VOA889-039

40

Body Front Section – Repair Group 50

Body Repair

VOA889-040

Body Center Section – Repair Group 51

41

Body Repair

VOA889-041

42

Body Center Section – Repair Group 51

Body Repair

Plastic

VOA889-042

Body Rear Section – Repair Group 53

43

Body Repair

VOA889-043

44

Body Rear Section – Repair Group 53

Special Tools

After the body shell has been assembled, the attachment points for the steering gear (at alignment fixture reference points 15) are gauged in reference to the suspension strut tower attachment points (at alignment fixtures 8 and 9). Adjustments are made using welded shims to achieve the tolerances required by the steering gear.

These shims are available as replacement parts.

VAS 6130

VOA889-044b

VAS 6130

VOA889-044d

45

Special Tools

The headlight mounts must be aligned using portal gauge VAS 5007 with alignment fixtures 44 and 45 before welding them into position or the panel joints will be misaligned.

Alignment fixtures 42, 43, 44, and 45 are supplied with portal gauge VAS 5007/14.

Airbag sensor mounts must be welded in place using VAS 5007 with alignment fixtures 42 and 43. They should be installed after completing other body repairs to minimize variations caused by welding.

VAS 5007/14

VOA889-045a

46

Special Tools

VAS 5007/14

VOA889-045b

47

Notes

48

Notes

49

Volkswagen of America, Inc. 3800 Hamlin Road Auburn Hills, MI 48326 Printed in U.S.A. August 2003