Phaeton Body Manual

PhaetonBody Manual

Student Reference

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 08/2003

©2003 Volkswagen of America, Inc.

All rights reserved. All information containedin this manual is based on the latestinformation available at the time of printingand is subject to the copyright and otherintellectual property rights of Volkswagen ofAmerica, Inc., its affiliated companies and itslicensors. All rights are reserved to makechanges at any time without notice. No partof this document may be reproduced,stored in a retrieval system, or transmittedin any form or by any means, electronic,mechanical, photocopying, recording orotherwise, nor may these materials bemodified or reposted to other sites withoutthe prior expressed written permission ofthe publisher.

All requests for permission to copy andredistribute information should be referredto Volkswagen of America, Inc.

Always check Technical Bulletins and theVolkswagen Worldwide Repair InformationSystem for information that may supersedeany information included in this booklet.

Trademarks: All brand names and productnames used in this manual are trade names,service marks, trademarks, or registeredtrademarks; and are the property of theirrespective owners.

i

Table of Contents

The Service Training Student Reference provides youwith information regarding designs and functions.

The Service Training Student Reference

is not a Repair Manual!

For maintenance and repair work, always refer tothe current technical literature

Important/Note!

New!

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

Vehicle Identification Number Plate .......................................................... 33

Bonded Joints ............................................................................................. 34

Body Insulation ........................................................................................... 35

Body Cavity Sealing .................................................................................... 39

Body Repair ................................................................................................. 40

Special Tools ................................................................................................ 45

Specifications

1

Specifications

• Length

199.02 inches (5055 mm)

• Width

74.92 inches (1903 mm)

• Height

57.09 inches (1450 mm)

• Wheelbase

113.43 inches (2881 mm)

• Turning circle

39.4 feet (12 m)

• Fuel tank capacity

23.8 gallons (90 liters)

• Front track width

64.09 inches (1628 mm)

64.09 in(1628 mm)

• Rear track width

63.46 inches (1612 mm)

• Permitted gross vehicle weight

5732 – 6592 pounds (2600 – 2990 kg)(depending on the engine)

• Curb weight

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

• Luggage compartment space

17.7 cubic feet (500 liters)

• Drag coefficient

0.32 CD

SSP270/118

199.02 in(5055 mm)

41.38 in(1051 mm)

113.43 in(2881 mm)

44.13 in(1121 mm)

63.46 in(1612 mm)

57.09 in(1450 mm)

74.92 in(1903 mm)

Front Bumper and Fenders

2

VOA889-003b

The front bumpercomponents are plastic.

Special Fasteners

The front fenders are plastic.

The front bumper and fendersare attached with screws fromthe inside.

The spoilers and chrometrim strips are attachedwith clips and can bereplaced separately.

Front Fenders – Repair Group 50Bumpers – Repair Group 63

VOA889-003a

3

Front Bumper Support

VOA889-004c

An additional support is installedbetween the longitudinal frame membersjust behind the front bumper components.

The Right DistanceRegulation Sensor G259is attached to the frontright bumper deformationelement on Phaetonsequipped with the AdaptiveCruise Control feature.

The sensor cover mustonly be painted withmillimeter-wave permeablecolor. It must not berecoated on the inside orthe outside, and must notbe covered.

Metal

Plastic

Bumpers – Repair Group 63

VOA889-004b

VOA889-004a

Rear Bumper

4

The rear bumpercomponents are plastic.

Metal

PlasticVOA889-010b

The chrome trim covers forthe exhaust system areattached to the rear bumper.

Bumpers – Repair Group 63

VOA889-010a

Trailer hitch optionsmay vary dependingupon marketing area.

Hood

5

VOA889-005

The hood is aluminum.

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

Hood – Repair Group 55

6

Front Doors

VOA889-006

Metal

Rubber

The front doors arealuminum. Laser-weldedaluminum die castings andextruded sections providefour times the rigidity of aconventional design.

Door seals are self-adhesive.

The door sealscannot be removedwithout damage. Ifremoved, they mustbe replaced.

Newly developedwindow guides ensuresmooth operation andreduce wind noise.

Front Doors – Repair Group 57

7

Front Doors

VOA889-007

Basic front door design is similarto other Volkswagen models.

Front Doors – Repair Group 57

Rear Doors

8

VOA889-008

Metal

RubberThe rear doors are aluminum.Laser-welded aluminum diecastings and extruded sectionsprovide four times the rigidityof a conventional design.

Door seals are self-adhesive.

The door sealscannot be removedwithout damage.If removed, theymust be replaced.

Newly developedwindow guides ensuresmooth operation andreduce wind noise.

Rear Doors – Repair Group 58

Rear Doors

9

VOA889-009

Basic rear door design is similarto other Volkswagen models.

Rear Doors – Repair Group 58

10

Luggage Compartment Lid

The standard luggage compartment lid is openedand closed manually with an electrical assist.

Emergency opening is achieved mechanicallywith the key inserted in the lock mechanismin the VW emblem on the lid.

Lids – Repair Group 55

11


VOA889-024

Metal


12


The Rear Lid Lock Button (in Luggage Compartment) E406in the luggage compartment lid is used to close the lid.

To open the power-assisted luggagecompartment lid, operate eitherthe switch on the door panel, themicroswitch in the VW emblem onthe lid, or the radio remote control.

Emergency opening is achievedmechanically with the keyinserted in the lock mechanismin the VW emblem on the lid.


13


VOA889-025

Metal

Aluminum

The power-assistedluggage compartment lid isopened and closed by anelectro-hydraulic mechanism.


14

Exterior Lights

VOA889-026

All front lighting elements exceptfog lights are integrated into thefront headlight housings.

The rear seatsmust be removedto replace the centerhigh-mountedbrake light. Rear light elements

are LEDs, except for thebackup lights which usea replaceable HPL bulb.

Rear light assemblies arealignment adjustable.

Front fog lights aremounted in the bumper.They use H11 lampsbehind transparent lenses.

Standard lighting includes xenon headlightswith gas discharge low-beam lamps andHB 3 high-beam lamps.

Exterior Lights – Repair Group 94

15

Mirrors

VOA889-011

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

Special Fastener

Glass

The outside rearview mirrors featurepower adjustment, power fold, automaticdimming, side turn signal lights, andsurround lighting.

The outside mirror housing,turn signals, and surroundlighting components can allbe replaced separately.

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

16

Glass

VOA889-012

Glass

Rubber

The Phaeton windshield is not precoated.New windshields must be pretreated inaccordance with Repair Manual instructionsbefore installation.

Rain/Light Recognition Sensor G397 isinstalled at the top center of the windshield.

The rubber seal bondedto the windshield can bereplaced separately.

Glass – Repair Group 64

17

Glass

VOA889-013

Glass

Rubber

The rear window is not precoated.New rear windows must be pretreatedin accordance with Repair Manualinstructions before installation.

Tungsten heating elementsand all antennas are integratedinto the rear window.

The rubber sealsbonded to therear window canbe replaced separately.

Glass – Repair Group 64

18

Exterior Trim

VOA889-014

Plastic

Metal

Aluminum

The plastic clips that retainthe roof trim strips are wedgedinto the roof joint.

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

Exterior Trim – Repair Group 66

19

Exterior Trim

VOA889-015

The rain channelmoldings at theA-pillars are attachedwith rivetedretaining clips.

Metal

Glass

Rubber

Aluminum

Exterior Trim – Repair Group 66

20

Sunroof

VOA889-020

A tilt and slide sunroof is availableon the Phaeton.

The wind deflector is controlledelectro-mechanically to reducewind noise and drafts, dependingon the driving speed and theamount the sunroof is open.

The sunshade moves at thesame time that the sunroof glassis opened or closed, but it canalso be separately controlledelectrically regardless of theposition of the glass.

Plastic

Glass

Sunroof – Repair Group 60

21

Instrument Panel

VOA889-016

The instrument panel topcovers and panels can bereplaced separately.

The front parkingaid displays in thedefroster panel area new feature.

Wood trim elements arereplaceable separately.

Interior Trim – Repair Group 70

Instrument Panel

22

VOA889-017

Special Parts

The multi-part instrument panelis attached to an aluminum carrierthat also acts as an air duct.

Instrument panelalignment todoor trim panelsis optimized bythe use ofspecial shims.


23

Console

VOA889-030

Four-seat Phaetons havefull-length center consoles.

Full-length center consoles includefront and rear seat center armrests,cupholders, phone and miscellaneousstorage, rear air vents, rear seatcontrols, and rear AC controls.


24

Console

VOA889-031


25

Console

VOA889-032

Five-seat Phaetons haveshort center consoles.

Short center consolesinclude front seat centerarmrests, cupholders,phone and miscellaneousstorage, and rear air vents.


26

Interior Trim

VOA889-018

Plastic

The interior trim panels arefastened with a combinationof clips and screws.

The sides of the rear shelftrim panel are connectedto the bottom edges of theC-pillar trim panels.


27

Interior Trim

VOA889-019

The roof insulation andreinforcements are bonded.

The headliner is held in placeby the pillar trim panels.

Plastic

Metal

The carpeting provides noise insulation andis comprised of three separate sections.

The insulation panel forward of theinstrument panel is installed flush with thebottom of the windshield.

If this insulation panel isdamaged during windshieldreplacement, it must alsobe replaced.


28

Luggage Compartment Trim

VOA889-021

The luggage compartmenttrim panels are fastenedwith a combination of clipsand screws.

Plastic

Metal


29


VOA889-022


30


VOA889-023

Several control modules areinstalled on the insulation panelunder the rear shelf.

Plastic

There is an additional trim panelin the luggage compartmentbehind the rear seatback.


31

Front Seats

VOA889-028

Front seats are newdesigns and are availablein 12-way and 18-wayadjustable versions.

Different front seat variants have differentcomfort features depending upon theirconfiguration and optional equipment.

The optional automatic lap beltmust be separated from the18-position front seats in orderto remove these seats.

All front seats on the Phaetonare equipped with an activeheadrest system.

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

32

Rear Seats

VOA889-029

The Phaeton is available with astandard or premium full-width rearbench seat, or 10-position individualrear seats with a center consolebetween them.

Different rear seat variantshave different comfort featuresdepending upon their configurationand optional equipment.

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

3 D

33

Vehicle Identification Number Plate

VOA889-027

In addition to the VIN located on the front leftedge of the instrument panel that is visiblethrough the windshield, the vehicle identificationnumber is stamped in the upper support forthe right front fender.

The model designation is 3D.

Special Parts

PR lables are attached to the body in theluggage compartment just forward of thespare wheel recess.

General – Repair Group 00

Bonded Joints

34

VOA889-037

In addition to welding, high-stress areas ofthe body are reinforced with an epoxy resinbond to ensure rigidity.

Epoxy Adhesive

Body Insulation

35

VOA889-033

Body insulation is used to reducenoise levels in the Phaeton.

Special Parts

Some body insulation is installedduring body shell assembly

36

Body Insulation

VOA889-034

Special Parts

37

Body Insulation

VOA889-035

Special Parts

Some body insulation is applied duringfinal body assembly stages.

38

Body Insulation

VOA889-036

Special Parts

39

Body Cavity Sealing

VOA889-038

Special Body Cavity Sealing Areas

40

Body Repair

VOA889-039

The Phaeton main bodystructure consists of high-gradeand super high-strength steelsand is completely galvanizedfor corrosion protection.

Body Front Section – Repair Group 50

41

Body Repair

VOA889-040

Body Center Section – Repair Group 51

42

Body Repair

VOA889-041

Body Center Section – Repair Group 51

43

Body Repair

VOA889-042

Plastic

Body Rear Section – Repair Group 53

44

Body Repair

VOA889-043

Body Rear Section – Repair Group 53

45

Special Tools

After the body shell has been assembled, theattachment points for the steering gear (at alignmentfixture reference points 15) are gauged in referenceto the suspension strut tower attachment points(at alignment fixtures 8 and 9).

Adjustments are made using welded shims toachieve the tolerances required by the steering gear.

These shims are availableas replacement parts.

VOA889-044d

VOA889-044b

VAS 6130

VAS 6130

Special Tools

46

VOA889-045a

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

Airbag sensor mounts must bewelded in place using VAS 5007with alignment fixtures 42 and 43.

They should be installedafter completing otherbody repairs to minimizevariations causedby welding.

The headlight mountsmust be aligned using portalgauge VAS 5007 withalignment fixtures 44 and 45before welding them intoposition or the panel jointswill be misaligned.

VAS 5007/14

Special Tools

47

VOA889-045b

VAS 5007/14

48

Notes

49

Notes

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

Documents

Phaeton Body Manual