Volkswagen 2K3 054 630 Manual De Montaje página 20

Note
Take the height (130 mm) from the bottom of the rear doors. Place a level on the bottom and keep it horizontal.
Starting from the level, move a distance of 130 mm vertically downwards.
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Remove the bumper covering.
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Exterior bodywork tasks; Repair Group 63; bumper; rear bumper; removing and refitting the bumper covering
Page 2 - figure 3
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Unscrew the hexagon-head nuts -arrows- and take the bumper bar out of the bumper covering.
Page 3 - figure 1
Note
The doubled bumper wall thickness is too thick for fitting the sensors and must be reduced to a single thickness.
Observe the following sequence to drill the holes exactly.
Figure A: Start the marked drilling points on the bumper covering and drill with a ∅ 2 mm drill.
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Figure B: Drill the inner bumper bar -2- at the predrilled points using a Forstner bit ∅ to 40 mm.
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Figure C: Drill the outer bumper wall -1- at the predrilled points using a Forstner bit ∅ to 26 mm.
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To prevent rotating of the spacers, an upward-pointing notch -arrow- about 2 mm deep is needed in the boreholes.
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File an upward-pointing notch -arrow- with a small triangular file in all four boreholes.
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Remove the swarf from the holes for the spacers in the bumper covering.
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Remove the right hand side boot trim from the vehicle.

Interior bodywork fitting; Repair Group 70; door trims/steaming; loading area and boot trims
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Switch off all electrical equipment and the ignition, and remove the ignition key from the ignition.
Page 3 - figure 2
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Place the individual sensor harness from the sensor harness* leading from the inside of the bumper covering to
the outside. At the same time, note the wire numbering; wire 1 must face forwards in the left hand hole drilled in
the bumper covering, and the remaining wires 2...4 must be fitted consecutively.
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Degrease the site for fitting the cable tie retaining plates* -1- inside the bumper covering with a suitable cleaner,
e.g. industrial alcohol.
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Bond the retaining plates -1- in position and secure the wiring to the retaining plates -1- using cable ties*.
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Remove the original grommet -arrow-.
Note
Vehicles with a tow hook are already fitted with a grommet instead of the stop -arrow-; in this case, do not use the
grommet delivered with the sensor harness. Make an extra hole in the existing grommet and pull the sensor harness
through this into the interior of the car. Seal the extra hole in the grommet with a suitable sealant.
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Refit the bumper covering following the same sequence in reverse, at the same time pulling the harness through
the opening inside the car -arrow-.
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Close the opening inside the car with the grommet -arrow- from the harness.
Page 4 - figure 1
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Degrease the fitting site (right hand side of the boot) for the control unit -2- for the parking distance control system
using a suitable cleaning agent, e.g. industrial alcohol.
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Fit the control unit* -2- in the boot using the double-sided adhesive tape provided.
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Degrease the fitting site (right hand side of the boot) for the buzzer unit -1- for the parking distance control system
using a suitable cleaning agent, e.g. industrial alcohol.
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Fit the buzzer* -1- in the boot using the double-sided adhesive tape* provided.
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Connect the black wire from the harness to the vehicle earthing point -arrow-.
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Wind in approx. 50 mm of the vehicle wiring, as shown in the diagram.
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Disconnect the wire at the right rear light of the vehicle (connector, terminal location 5).
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Clamp one end of the wire -3- in a duraseal connector* -4-.
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Clamp the free end of the wire -6- and the red wire -5- from the wiring together in the duraseal connector -4-.
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Heat-shrink the duraseal connector -4- to seal it, using the hot air blower from the harness repair set -VAS 1978-.
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Renew the harness protective tape.
Page 4 - figure 2
Note
The connectors -1- are designed such that they can only be plugged into the sockets on the controller -3 - in one position.
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Plug the sensor connectors -1- according to their numbering into the sockets "1" to "4" on the controller -3-, until
they click into the fixed position.
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*please refer to the set contents