Volkswagen Jetta 2005 Body Repair Manual Download Page 216

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Renewing C-pillar reinforcement

WARNING

Observe safety notes!

⇒ General Information; Body Repairs, General Body Repairs ;

Safety instructions
• Side panel already removed

⇒ “6 Renewing side panel - partial replacement”, page 201

Jetta 2005 ➤

Body Repairs - Edition 04.2009

210

Rep. Gr.53 - Body - rear

Summary of Contents for Jetta 2005

Page 1: ...r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t...

Page 2: ...h t b y V o l k s w a g e n A G Repair Group overview for Body Repairs Repair Group 00 Technical data 50 Body front 51 Body centre 53 Body rear Technical information should always be available to the...

Page 3: ...s 9 6 1 Body 9 6 2 Floor group 10 7 Body panel gaps shut lines 12 7 1 Body front 12 7 2 Body centre 14 7 3 Body rear 15 8 Body dimensions 18 8 1 Body front 18 8 2 Body centre 23 8 3 Body rear 28 8 4 F...

Page 4: ...ving 86 10 2 Installing 87 51 Body centre 89 1 Renewing roof 89 1 1 Removing 90 1 2 Installing 91 2 Renewing front roof cross member 102 2 1 Removing 102 2 2 Installing 103 3 Renewing roof reinforceme...

Page 5: ...70 1 Renewing cross panel 170 1 1 Removing 171 1 2 Installing 172 2 Renewing mounting plate 182 2 1 Removing 183 2 2 Installing 183 3 Renewing luggage compartment floor 186 3 1 Removing 187 3 2 Instal...

Page 6: ...l e i s n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o...

Page 7: ...n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 00 Technical data 1 Vehicle identification data 1 1 Vehicle identification number The vehicle identificati...

Page 8: ...uaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1...

Page 9: ...doesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g...

Page 10: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Safety instructions WARNING Before beginning an...

Page 11: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Moulded foam elements On this vehicle various bodywork cavities are fitted with moulded...

Page 12: ...p y r i g h t b y V o l k s w a g e n A G 4 Laser welding On this vehicle some sections of the roof and body are welded by laser With laser welding a high energy beam of light is directed over the sea...

Page 13: ...d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 Galvanized body parts Note Before carrying out body repairs observe the following information General Information Body Repairs General...

Page 14: ...c c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 2 Floor gr...

Page 15: ...r i g h t b y V o l k s w a g e n A G 6 High strength body parts Note Before carrying out body repairs observe the following information General Information Body Repairs General Body Repairs 6 1 Body...

Page 16: ...uaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 6...

Page 17: ...p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G The shaded body panels are manufactured of high strength or...

Page 18: ...oesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e...

Page 19: ...o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i...

Page 20: ...e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i...

Page 21: ...e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n...

Page 22: ...n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t...

Page 23: ...o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i...

Page 24: ...C o p y r i g h t b y V o l k s w a g e n A G 8 Body dimensions Note Dimensions only given for checking purposes Alignment bracket set for Touran VAS 6240 alignment bracket set supplement Golf 2004 VA...

Page 25: ...p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i...

Page 26: ...r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t...

Page 27: ...p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i...

Page 28: ...e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d...

Page 29: ...u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c...

Page 30: ...t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d...

Page 31: ...p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i...

Page 32: ...r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t...

Page 33: ...p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i...

Page 34: ...n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m...

Page 35: ...t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s...

Page 36: ...e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o...

Page 37: ...sedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y...

Page 38: ...uthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C...

Page 39: ...e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n...

Page 40: ...t guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A...

Page 41: ...ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t...

Page 42: ...VolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g...

Page 43: ...isedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y...

Page 44: ...VolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g...

Page 45: ...e number in the figures are identical to the final digits on the alignment bracket AB The required basic size for the straightening bracket is given Alignment bracket set for Touran VAS 6240 alignment...

Page 46: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 1 Overview 2 MZ 142 and TV 400 3 belongs to item 2 4 belongs to item 2 8 MZ 140 and TV 400 10 MZ 200 12 MZ 26...

Page 47: ...t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 2 Front alignment...

Page 48: ...AG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V...

Page 49: ...swagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t...

Page 50: ...t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 Mounting point for...

Page 51: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 Straightening bracket mounting point for front longi tudinal member 12 St...

Page 52: ...doesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g...

Page 53: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a...

Page 54: ...b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 4 Rear alignment bracket 34 Moun...

Page 55: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 34 Straightening bracket mounting for front lo...

Page 56: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G 10 Portal gauge 10 1 Overview Special tools and workshop equipment required Alignment bracket set for Touran VAS 6240 Alignment bracket set sup...

Page 57: ...ranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 10...

Page 58: ...p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 50 Body front RO...

Page 59: ...p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove remaining...

Page 60: ...i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i...

Page 61: ...Gdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g...

Page 62: ...isedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y...

Page 63: ...c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 2 Installing 2 2 1 Preparing new part Replacement part Left en...

Page 64: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 43 55 00 3 Renewing retaining bracket for subframe WARNING Observe safety notes General Informati...

Page 65: ...n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release original joint Remove remaining material 3 2 Installing 3 2 1 Preparing new part Re...

Page 66: ...t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i...

Page 67: ...p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 65 55 00 4...

Page 68: ...i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release original joint Release origi...

Page 69: ...genAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b...

Page 70: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 72 55 00 5 Renewing upper wheel housing...

Page 71: ...t C o p y r i g h t b y V o l k s w a g e n A G 5 1 Removing Release original joint Release original joint Remove remaining material 5 2 Installing 5 2 1 Preparing new part Replacement part Upper inn...

Page 72: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld longitudinal member for upper inner wheel housing SG plug weld seam Note New part mus...

Page 73: ...a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 72 55 02 6 Renewing upper longitudinal mem ber for wheel housing partial renew al WARNING Observe safety note...

Page 74: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Dimension a 170 mm Release original joint Make parting cut on inner longitud...

Page 75: ...part to fit and secure in position with vehicle stand ing on alignment bracket set Check fit with add on parts Weld longitudinal member for upper inner wheel housing RP spot weld seam Weld parting cut...

Page 76: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 74 55 50 7 Renewing front wheel housing WARNING Observe safety notes General I...

Page 77: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 2 Installing 7 2 1 Preparing new part Replacement part Wheel housing 7 2 2 Welding in Adapt new par...

Page 78: ...k s w a g e n A G RO 50 79 49 50 8 Repairing threads for securing sub frame suspension subframe WARNING Observe safety notes General Information Body Repairs General Body Repairs Safety instructions...

Page 79: ...t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Helicoil thread insert 8 1 Contents of...

Page 80: ...i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 2 Repairing thread 8 2 1 Drilling...

Page 81: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 2 2 Cutting thread Cut thread with a thread tap Clean threaded sleeve blow out wit...

Page 82: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Turn threaded mounting into the threaded plate until the threa ded mounting is flush with the threaded plate from the exterior...

Page 83: ...e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 79 55 03 9 Renewing front longitudinal member WAR...

Page 84: ...t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i...

Page 85: ...y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Do not damage mountin...

Page 86: ...VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o...

Page 87: ...n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Transfer parting cut to new part and cut out Drill 7 mm holes for SG plug weld seam 9 2 2 Welding in Adapt new part to fit...

Page 88: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 2 3 Shortening new longitudinal memb...

Page 89: ...s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Fit alignment bracket mounting for front longitudinal memb...

Page 90: ...t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Secure front bumper bracket for front longitudinal member 1 using RW 1...

Page 91: ...r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 50 79 55 06 10 Renewing front longitudinal member p...

Page 92: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a...

Page 93: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove remaining material 10 2 Installing 10 2 1 Preparing new part Replacement part Longitudinal member subpart Cover plate for longitudinal mem...

Page 94: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Recreate original joint RP spot weld seam Note Distance between weld points a approx 35 40 mm Weld cover...

Page 95: ...e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 51 Body centre RO 51 03 55 00 1 Renewing roof WARNING Observe...

Page 96: ...risedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p...

Page 97: ...n t C o p y r i g h t b y V o l k s w a g e n A G Remove remaining material Note When removing the remaining material 1 from the roof make sure that the side elements roof side mem ber 2 are not dama...

Page 98: ...k s w a g e n A G 2K body adhesive D 180 KD3 A2 2 cartridge sets Adhesive sealant AKD 476 KD5 05 Primer ALN 002 003 04 Felt 533 867 910 B Note Following repair sequence must be adhered to in order to...

Page 99: ...e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G As required place approx 6 10 felt pads 1 on roof frame...

Page 100: ...t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Tension two securing belts commercially available across roof Align front belt arrow with marking 1 in front door open...

Page 101: ...t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 2 Adjusting roof depth By tightening and loosening the securin...

Page 102: ...g h t b y V o l k s w a g e n A G Use a drill bit 3 5 mm to check dimension a drill bit 4 must be able to slide between roof 2 and securing belt 1 without much resistance If necessary change felt pads...

Page 103: ...e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Cut approx 2 mm off nozzle B to provide appropriate bead...

Page 104: ...t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Apply 1K assembly adhesive D 190 MKD A3 A in area of roof member using pneumatic cartridge gun V A G 1761 1 Apply 1K...

Page 105: ...37 without static mixer until the adhesive is discharged uniformly from both chambers of the cartridge connecter Then screw the static mixer onto the cartridge connector Apply the first 100 mm of adhe...

Page 106: ...for the roof 1 2 2 Adjusting roof depth page 95 Note After bonding the vehicle must stand on a level surface for 8 10 hours at room temperature at least 15 C so that the bonding components are able t...

Page 107: ...sauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t...

Page 108: ...i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 07 55 50 2 Renewing front roof...

Page 109: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove residues at transition t...

Page 110: ...nAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y...

Page 111: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 08 55 50 3 Renewing roof reinfor...

Page 112: ...e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove residues on left and right roof frame 3 2 Installing 3...

Page 113: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 09 55 50 4 Renewing rear roof cross member...

Page 114: ...y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove residues at transi...

Page 115: ...lkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h...

Page 116: ...e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 37 55 00 5 Renewing A pillar partial renewal WARNING Observe safety notes Welding parti...

Page 117: ...agenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s...

Page 118: ...uaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5...

Page 119: ...b y V o l k s w a g e n A G Remove adhesive remains completely and grind adhesive surfaces back to bare metal 5 2 Installing 5 2 1 Preparing new part Replacement part A pillar subpart with side membe...

Page 120: ...d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 2 3 Welding in Apply 2 K body adhesive D 180 KD3 A2 in the area of the factory bonding and in the door aperture area Apply an adhesive c...

Page 121: ...s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld parting cuts and connecting area to reinforcement fo...

Page 122: ...n A G RO 51 38 55 50 6 Renewing A pillar reinforcement WARNING Observe safety notes Welding parting using spark generating machines tools or tin ning in foam treated areas creates gases which are haz...

Page 123: ...t guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A...

Page 124: ...VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o...

Page 125: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove remaining material 6 2 Installing 6 2 1 Preparing new part Replacement part A pillar reinforcement with web plate f...

Page 126: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 6 2 3 Welding in Apply 2 K body adhesive D 180 KD3 A2 in the area of the door aperture N...

Page 127: ...s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld in A pillar reinforcement SG plug weld seam and RP s...

Page 128: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 41 55 00 7 Renewing B pillar DANGER Observe safety notes Welding parting using...

Page 129: ...enAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y...

Page 130: ...l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e...

Page 131: ...te Make parting cuts with pneumatic jig saw V A G 1523 only Do not damage internal reinforcements Note cut line figure page 123 If the B pillar reinforcement also needs to be replaced the front part o...

Page 132: ...aranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pa...

Page 133: ...e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove remaining material Remove adhesive remains completely and grind adhesive surfaces back...

Page 134: ...y V o l k s w a g e n A G 7 2 2 Marking area where no welding work may be carried out Note When welding in B pillar welding work must not be carried out in the areas marked on the illustrations for c...

Page 135: ...o l k s w a g e n A G 7 2 4 Welding in Place backing plate behind side panel parting cut Note Holes for door hinges in area 1 must remain free of adhesive New part must be welded within 20 minutes ot...

Page 136: ...enAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w...

Page 137: ...oesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e...

Page 138: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 42 55 50 8 Renewing B pillar reinforcement DANGER Observe safety notes Welding parting using spark generating machi...

Page 139: ...ot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A...

Page 140: ...h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 1 Removing Note B pillar reinforcement must only be cut at the point indicated 1 Cutting or welding at a point other than the one...

Page 141: ...swagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k...

Page 142: ...oesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e...

Page 143: ...o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 2 Installing 8 2 1 Preparing new part Replacement part B pillar reinforcement Front side member reinforcement Rear side member reinforceme...

Page 144: ...Welding the outer curvatures also weakens the construction The enlargements show the tacking points of the front side member reinforcement and the B pillar rein forcement This illustration is basical...

Page 145: ...e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld side member front reinforcement 3 to B pillar reinforce...

Page 146: ...king areas where no welding work may be carried out Note When welding in B pillar reinforcement welding work must not be carried out in areas marked on the illus trations for crash safety reasons The...

Page 147: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 2 4 Welding in Note New part must be welded in within 20 minutes or adhesion properties of adhe...

Page 148: ...agenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s...

Page 149: ...sauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t...

Page 150: ...snot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n...

Page 151: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 45 55 00 9 Renewing side member WARNING Observe safety notes Welding parting usin...

Page 152: ...d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o...

Page 153: ...o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 1 Removing Note Make parting cuts with pneumatic jig saw V A G 1523 only When making parting cut 3...

Page 154: ...n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release original joint to side member reinforcement Remove remaining material Remove remaining adhesive co...

Page 155: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Transfer parting cut to new part and cut out Apply 2 K body adhesive D 180 KD3 A2 on adhesive area...

Page 156: ...s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 2 3 Marking area where no welding work may be carried out Note When welding in side member welding work must not be carried out in ar...

Page 157: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Holes for door hinges in area 2 must remain free of adhesive New part must be welded within 20 minutes otherwise adhesive properties of adhe...

Page 158: ...r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Note that no welding work may be carried out in areas 1 Butt weld parting cu...

Page 159: ...oesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e...

Page 160: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 49 55 50 10 Renewing side...

Page 161: ...orisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p...

Page 162: ...nAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a...

Page 163: ...p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 10 2 Installing 10 2 1 Preparing new part Replacement part...

Page 164: ...e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld original j...

Page 165: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 49 55 52 11 Renewing side member...

Page 166: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 11 1 Removing 1 Inner side panel 2 Wheel housing liner 3 Cutting point Make parting cut as shown behind the inn...

Page 167: ...s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Transfer parting cut to new part and cut it 11 2 2 Welding...

Page 168: ...y V o l k s w a g e n A G RO 51 69 55 56 12 Renewing seat cross member mounting outer WARNING Observe safety notes General Information Body Repairs General Body Repairs Safety instructions Note If a t...

Page 169: ...n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 12 1 Removing Note When...

Page 170: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 12 2 Installing 12 2 1 Preparing new part Repl...

Page 171: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 69 55 58 13 Renewing seat cross member mounting on Tunnel WARNING Observe safety notes General I...

Page 172: ...e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 13 1 Removing N...

Page 173: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 13 2 Installing 13 2 1 Preparing new part Replacement part Seat cross member mountin...

Page 174: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 51 87 55 50 14 Renewing seat cross member...

Page 175: ...C o p y r i g h t b y V o l k s w a g e n A G 14 1 Removing Note When separating laser welded seams ensure that the panels ly ing behind are not damaged Release original joint Remove remaining materia...

Page 176: ...snot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n...

Page 177: ...t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s...

Page 178: ...c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove remaining material 1 2 Installing 1 2 1 Preparing new part Replacement part Note The replacement part is delivered without recesses fo...

Page 179: ...n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m...

Page 180: ...n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note New part must be welded in within 20 minutes or adhesion properties of adhesive will be impaired App...

Page 181: ...rac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note When...

Page 182: ...t C o p y r i g h t b y V o l k s w a g e n A G 1 2 3 Cutting out recesses for the tail light Note The left side of the vehicle is shown The figure and the work apply analogously for the right side of...

Page 183: ...r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Dimensions for the recesses for the tail light Dimensi...

Page 184: ...orac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 4 Ins...

Page 185: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note The left side of the vehicle is shown The figure and the work apply analogousl...

Page 186: ...t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Only the left...

Page 187: ...n A G Note The welding bolts for the left guide 1 and the securing strip 2 are depicted Building up weld studs on the right side of the vehicle is done analogously Weld the welding bolts for the guide...

Page 188: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a...

Page 189: ...t C o p y r i g h t b y V o l k s w a g e n A G 2 1 Removing Release original joint Remove remaining material 2 2 Installing 2 2 1 Preparing new part Replacement part Note The replacement part is del...

Page 190: ...wagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s...

Page 191: ...t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note When welding tail light mounting with upper side panel use a heat shield to prevent damage to side panel paintwork Weld in ta...

Page 192: ...s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 24 55 50 3 Renewing luggage compartment floor WARNING Observe safety notes Welding parting using spark generating machines tools o...

Page 193: ...nAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a...

Page 194: ...isedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y...

Page 195: ...uaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G R...

Page 196: ...t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Drill holes for SG plug weld seam 7 mm distance approx 20 mm 3 2 2 Moul...

Page 197: ...agenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b...

Page 198: ...edbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r...

Page 199: ...o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 47 55 50 4 Renewing longitudinal member par tial renewal WARNING Observe safety notes General...

Page 200: ...AGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a...

Page 201: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 2 Installing 4 2 1 Preparing new part Replacement part Longitudinal member...

Page 202: ...c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld in new p...

Page 203: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 48 55 50 5 Renewing rear longitudinal member end piece WARNING Observe safety not...

Page 204: ...nteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 1 R...

Page 205: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 2 Installing 5 2 1 Preparing new part Replacement part Longitudinal member Exhaust pipe...

Page 206: ...uaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G W...

Page 207: ...n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 55 55 00 6 Renewing side panel partial re placement WARNING Observe safety notes Welding parting usi...

Page 208: ...e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o...

Page 209: ...t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 6 1 Removing Note Make parting cuts with pneumatic jig saw V A G 1523 only When making parting cut 2 keep overlap for...

Page 210: ...anteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Grin...

Page 211: ...t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release original joint Remove remaining material Remove remaining a...

Page 212: ...r i g h t b y V o l k s w a g e n A G Moulded foam element 2K body adhesive D 180 KD3 A2 Adhesive sealant AKD 476 KD5 05 Transfer parting cut to new part and cut out Drill holes on side panel as show...

Page 213: ...l otherwise the glued joint will not be durable No adhesive may be applied within 10 mm of a weld point 1 Before starting welding on right hand side panel apply butyl sealing cord in area of fuel fill...

Page 214: ...uthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C...

Page 215: ...o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld original joint in rear window aperture RP spot weld seam and SG plug weld seam Weld side panel to sealin...

Page 216: ...b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 29 55 50 7 Renewing C pilla...

Page 217: ...VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o...

Page 218: ...n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 2 Installing 7 2 1 Preparing new part Replacement part C pillar reinforcement Transfer parting cut to the new part and cut wh...

Page 219: ...h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 69 55 50 8 Renewing outer wheel housing liner WARNING Observe safet...

Page 220: ...s n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a...

Page 221: ...anteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 1...

Page 222: ...h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Make parting cuts with pneumatic jig saw V A G 1523 only Separate or...

Page 223: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 2 Installing 8 2 1 Welding in Replacement part Outer wheel housing liner 2K body adhesive D 180 KD3 A2 Note New part must be welded in within 20...

Page 224: ...G VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V...

Page 225: ...i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Weld outer wheel housing liner 2 to...

Page 226: ...m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G RO 53 80 55 50 9 Renewing spare wheel well partial renewal WARNING Observe safety notes General Information Body...

Page 227: ...esnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e...

Page 228: ...t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 Cutting point Transfer parting cut 1 to the new part and cut shad...

Page 229: ...enAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y...

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Volkswagen Jetta 2005, Body Repair Manual

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Summary of Contents for Jetta 2005

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