Volkswagen Jetta 2005 Скачать руководство пользователя страница 1

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Body Repairs

Jetta 2005 ➤

Edition 04.2009

Service

Service Department. Technical Information

Содержание Jetta 2005

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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