2005 VOLKSWAGEN JETTA BODY REPAIR MANUAL

Service

Body Repairs Jetta 2005 ➤ Edition 04.2009

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Service Department. Technical Information

Service

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Repair Group overview for Body Repairs

00 - Technical data 50 - Body - front

51 - Body - centre

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53 - Body - rear

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg

MEX5R006220

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Contents 1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Floor group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 High strength body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Floor group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Floor group - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Floor group - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Floor group - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Alignment jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lkswagen A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Front alignment AG. Vobracket do agen ksw alignment bracket . . e.s .no. t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 9.3 Centre o gu yV b a 9.4 risedRear alignment bracket . . . . . . . . . r.an.te. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o e th 10 Portal gauge . . . . . . . . . . . . . . . . . . . . .o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . au s s 10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 2 4 5 6 7 7 8 9 9 10 12 12 14 15 18 18 23 28 31 34 36 39 40 41 46 48 50 50

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1

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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 rrectness of i t to the co nf o r m spec atio h re n in wit

Renewing right-hand bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing left console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing retaining bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing front bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing upper longitudinal member for wheel housing - partial renewal . . . . . . . . . . . . thi sd o cu m en

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1 1.1 1.2 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 5 5.1 5.2 6

Contents

52 52 53 55 56 57 58 58 59 61 61 62 64 65 65 67

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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Contents

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Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing front roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing A-pillar - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing A-pillar reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing B-pillar reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing seat cross member mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing seat cross member mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

ii

67 68 70 70 71 72 73 74 77 78 80 85 86 87

. . . . . 89

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1 1.1 1.2 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 5 5.1 5.2 6 6.1 6.2 7 7.1 7.2 8 8.1 8.2 9 9.1 9.2 10 10.1 10.2 11 11.1 11.2 12 12.1 12.2 13

AG do agen es n ksw l o o - centre . . . . . . . . . . . . . .ed.b.y V. . . . . . . . . . . . . . . . . . . . t .gu.ar.a . . . . . . . . nt s ri Renewing roof . . . . . . . . .ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . a a Removing . . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . .

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51 - Body

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing front wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing threads for securing subframe (suspension subframe) . . . . . . . . . . . . . . . . . . . .

Contents of thread repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing front longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing front longitudinal member - partial replacement . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . A. G . ..V.o.lk.sw . a. g.e.n. . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.1 6.2 7 7.1 7.2 8 8.1 8.2 9 9.1 9.2 10 10.1 10.2

89 90 91 102 102 103 105 105 106 107 107 108 110 112 113 116 118 119 122 125 127 132 134 137 145 147 148 154 156 157 159 160 160 162 163 164 165

Jetta 2005 ➤ Body Repairs - Edition 04.2009 13.1 13.2 14 14.1 14.2

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

166 167 168 169 169

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170 171 172 182 183 183 186 187 189 193 194 195 197 198 199 201 203 205 210 211 212 213 215 217 220 220 221

do c um en

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

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1 Renewing cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Renewing mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Renewing luggage compartment floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Renewing longitudinal member - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Renewing rear longitudinal member end piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Renewing side panel - partial replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Removing n.A.G.. V. o. lk. s.w.a.ge. n. A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do age ksw . . . . . . . . . . . . . . . .e.s .no.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Installing Vol gu y ar db 7 iseRenewing C-pillar reinforcement . . . .an.te. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r o e h t 7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . .or.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . au c s s 7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Renewing outer wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Renewing spare wheel well - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ility ab y li an pt ce

un le

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Contents

iii

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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Contents

do c um en

iv

rrectness of i t to the co nform spec at i h re o n wit in t his

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

00 –

Technical data

1

Vehicle identification AG. Volkswagen AG d data agen o

Vehicle identification number

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1.1

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The vehicle identification number -arrow- is located on the right side of the vehicle in the area of the wing mounting.

More vehicle identification numbers are located on the right side of the vehicle on the outer seat console and on the front edge of the floor panel below the rear seat.

1. Vehicle identification data

1

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Identification plate

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AG.

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Rep. Gr.00 - Technical data

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2

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Vehicle data sticker

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1.3

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The identification plate -arrow- is located on is visible when the left front door is opened.

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1.2

Jetta 2005 ➤ Body Repairs - Edition 04.2009 The vehicle data sticker -arrow- is stuck in the spare wheel wheel on the left, as viewed when sat behind the steering wheel looking forwards.

rrectness of i t to the co nform spec at i h re o n wit in t his

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1. Vehicle identification data

3

AG.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

2

Safety instructions WARNING

Before beginning any cutting, alignment or dent removal, refer to safety notes in the binder General information, body repairs and general body repairs.

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Rep. Gr.00 - Technical data

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4

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Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes

Jetta 2005 ➤ Body Repairs - Edition 04.2009

3

Moulded foam elements

On this vehicle, various bodywork cavities are fitted with moulded foam elements. The moulded foam elements reduce the amount of driving noise that is transmitted into the interior.

The exact location of these moulded foam elements are shown at the beginning of the respective repair description.

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1 - Moulded foam element

3. Moulded foam elements

5

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AG.

Prote cted by c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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 seam to be welded by optical lenses or optical fibre.

During the welding process, the upper panel is melted onto the partially molten lower panel, creating a welded joint without the need of additional material.

For repairs other than roof repairs, the laser weld seam is re‐ placed by an SG plug weld seam or RP spot weld seam.

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Rep. Gr.00 - Technical data

thi sd o cu m en

6

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

5

Galvanized body parts Note

Before carrying out body repairs observe the following information ⇒ General Information; Body Repairs, General Body Repairs .

The vehicle consists of body panels which are galvanized on both sides and not galvanized panels.

5.1

Body

rrectness of i t to the co nform spec at i h re o n wit in t his

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The shaded body panels are not galvanized.

The wing and the side part shown in this diagram serve only as orientation and consist of body panels which are galvanized on both sides.

5. Galvanized body parts

7

Jetta 2005 ➤ Body Repairs - Edition 04.2009 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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8

Rep. Gr.00 - Technical data

AG.

The floor panel shown in this diagram serve only as orientation and consists of a body panel which is galvanized on both sides.

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The shaded body panels are not galvanized.

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Floor group

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5.2

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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

rrectness of i t to the co nf o r m spec atio h re n in wit

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The shaded body panels are manufactured of high strength or very high strength body panels. ht rig py Co t.

The reinforcements for front inner side panel -1- and B-pillar -1consist of “special quality steel”. The processing is described in repair chapter ⇒ page 137 . agen lksw Vo by

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Rear wing, side panel and roof shown in this figure serve only as orientation.

6. High strength body parts

9

AG.

Jetta 2005 ➤ Body Repairs - Edition 04.2009

6.2

Floor group

rrectness of i t to the co nform spec at i h re o n wit in t his

The shaded body panels are manufactured of high strength or very high strength body panels.

The floor panel is only shown for orientation purposes.

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Rep. Gr.00 - Technical data

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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The shaded body panels are manufactured of high strength or very high strength body panels.

The floor cross member -1- and the cross member reinforcement -1- consist of “special quality steel”.

The floor panel and the inner wheel housing shown in this diagram serve only as orientation.

6. High strength body parts

11

Jetta 2005 ➤ Body Repairs - Edition 04.2009

7

Body panel gaps/shut lines Note

♦ To adjust or check gaps, use special tool setting gauge

-3371- .

♦ Gaps are always given in millimetres.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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Rep. Gr.00 - Technical data

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12

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Body - front

ility ab y li an pt ce

7.1

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

7. Body panel gaps/shut lines

13

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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14

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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Body - centre

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7.2

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Body - rear

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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7.3

7. Body panel gaps/shut lines

15

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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Rep. Gr.00 - Technical data

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16

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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7. Body panel gaps/shut lines

17

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

8

Body dimensions Note

♦ Dimensions only given for checking purposes. Alignment

bracket set for Touran -VAS 6240- , alignment bracket set supplement Golf 2004▸ -VAS 6240/2- and alignment bracket set supplement Jetta 2005 ▸/Bora 2006 ▸ -VAS 6240/5- deci‐ sive.

♦ Bolts, screws, plugs, trim and attached components must be

removed before starting the measuring process.

♦ Use telescopic gauge -VAS 5159- or telescopic gauge -VAS

5160- to determine body dimensions.

8.1

Body - front

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Rep. Gr.00 - Technical data

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18

do c um en

Dimension -a- = 1,044 mm

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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Dimension -a- = 1,343 mm

8. Body dimensions

19

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

r fo ng

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Rep. Gr.00 - Technical data

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20

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or ac au = 1,406 mm Dimension s-as

Jetta 2005 ➤ Body Repairs - Edition 04.2009

do c um en

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Dimension -a- = 1,384 mm

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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8. Body dimensions

21

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Dimension -a- = 1,442 mm

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Rep. Gr.00 - Technical data

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22

thi sd o cu m en

Dimension -b- = 881 mm

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.2

Body - centre

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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8. Body dimensions

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Dimension -b- = 895 mm

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Dimension -a- = 885 mm

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23

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24

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Dimension -b- = 965 mm

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Dimension -a- = 716 mm

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Dimension -a- = 1,424 mm

8. Body dimensions

25

Jetta 2005 ➤ Body Repairs - Edition 04.2009

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Rep. Gr.00 - Technical data

thi sd o cu m en

26

rrectness of i t to the co nf o r m spec atio h re n in wit

Dimension -a- = 1,430 mm

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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Dimension -a- = 1,392 mm

8. Body dimensions

27

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C op yi

Body - rear

Rep. Gr.00 - Technical data

Prote cted by

28

AG.

Dimension -b- = 643 mm

agen lksw Vo by

c o p yri gh t .

C op yi

Dimension -a- = 1,280 mm

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8.3

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Dimension -b- = 549 mm

ht rig py Co t.

Dimension -a- = 1,123 mm

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8. Body dimensions

29

Jetta 2005 ➤ n AG. Volkswagen AG do es n wage Body Repairs - Edition 04.2009 o olks

t gu ara nte eo ra c

AG.

Prote cted by

Rep. Gr.00 - Technical data

agen lksw Vo by

c o p yri gh t.

C op yi

30

ht rig py Co t.

Dimension -b- = 1,103 mm

thi sd o cu m en

Dimension -a- = 1,424 mm

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Floor group - front

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ility ab y li an pt ce

do c um en

ht rig py Co t.

8.4

Jetta 2005 ➤ Repairs - Edition 04.2009

agen lksw Vo by

AG.

Prote cted by c o py rig ht .

C op yi

Dimension -a- = 828 mm Note

Vehicle from below, line of vision is to rear.

8. Body dimensions

31

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

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Prote cted by

Rep. Gr.00 - Technical data

AG.

32

agen lksw Vo by

c o p yri gh t .

C op yi

Vehicle from below, line of vision is to rear.

ht rig py Co t.

Note

do c um en

Dimension -a- = 1,103 mm

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

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do c um en

ht rig py Co t.

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AG.

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C op yi

Dimension -a- = 619 mm Note

Vehicle from below, line of vision is to rear.

8. Body dimensions

33

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Floor group - centre

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Prote cted by c o p yri gh t.

C op yi

agen lksw Vo by

AG.

Note

ht rig py Co t.

Dimension -a- = 1,455 mm

♦ This dimension is measured on the inside of the sill flange. ♦ Vehicle from below, line of vision is forwards.

34

Rep. Gr.00 - Technical data

do c um en

r te o iva r rp fo g n

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8.5

do c um en

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara ➤ d Jetta 2005 e nte is r o eo h Body Repairs - Edition 04.2009 ut ra a c s s

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AG.

Prote cted by c o py rig ht .

C op yi

Dimension -a- = 1,917 mm Note

Vehicle from below, line of vision is forwards.

8. Body dimensions

35

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Prote cted by

Vehicle from below, line of vision is forwards.

36

Rep. Gr.00 - Technical data

AG.

Note

agen lksw Vo by

c o p yri gh t.

C op yi

Dimension -b- = 1,076 mm

do c um en

r te o iva r rp fo g n

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Floor group - rear

ht rig py Co t.

8.6

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

Dimension -a- = 985 mm

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ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Dimension -b- = 985 mm Note

Vehicle from below, line of vision is forwards.

8. Body dimensions

37

Jetta 2005 ➤ Body Repairs - Edition 04.2009

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Dimension

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or ac -a-s a=u 1,043 mm s

Dimension -b- = 1,245 mm

rrectness of i t to the co nf o r m spec atio h re n in wit

Note

Vehicle from below, line of vision is forwards.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Rep. Gr.00 - Technical data

thi sd o cu m en

38

Jetta 2005 ➤ Body Repairs - Edition 04.2009

9

Alignment jig Note

♦ AB = Alignment bracket ♦ The article 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

bracket set supplement for Golf 2004 ▸ -VAS 6240/2- and alignment bracket set for Jetta 2005 ▸/Bora 2006 ▸ -VAS 6240/5-

♦ The right-hand side of the vehicle is depicted in the following

illustrations.

AG. Volkswagen AG d agen

oes ksw not ♦ Detailed information on setting Vol up the alignment bracket set g

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

r fo ng

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

To avoid damage to attached parts when placing vehicle on straightening jig, remove hindering components, such as wheel housing liners.

or ac

ht rig py Co t.

ss

ua ran tee

ri tho au

ility ab y li an pt ce

Note

un le

y can be found with the equipment. db se

9. Alignment jig

39

agen lksw Vo by

AG.

Prote cted by c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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 260 16 - MZ 602 17 - belongs to item 16 18 - belongs to item 16 19 - belongs to item 16 20 - MZ 140

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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22 - belongs to item 20

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24 - Front body control hole 26 - MZ 80

rrectness of i t to the co nf o r m spec atio h re n in wit

25 - belongs to item 24 28 - MZ 80 or MZ 140 30 - MZ 140

32 - belongs to item 30 34 - MZ 200 36 - MZ 602 40 - MZ 260

50 - MZ 141 and TV 400

ht rig py Co t.

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C op yi

Rep. Gr.00 - Technical data

thi sd o cu m en

40

Jetta 2005 ➤ Body Repairs - Edition 04.2009

9.2

Front alignment bracket

2 - Mounting point for longitu‐ dinal member front part 4 - Mounting point for top of longitudinal member 10 - Mounting point of engine mounting

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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11 - Mounting point of gearbox suspension

9. Alignment jig

41

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 2 - AB mounting for front part of longitudinal member 3 - Distance plate t gu ara nte eo ra c

yV db ise r tho au s s

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

Rep. Gr.00 - Technical data

ht rig py Co t.

42

do c um en

r te o iva r rp fo g n

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4 - AB mounting for upper lon‐ n AG. Volkswagen AG do es n wage gitudinal member o olks

Jetta 2005 ➤ Body Repairs - Edition 04.2009 10 - Straightening bracket mounting for engine mounting 11 - Straightening bracket mounting for gearbox mount‐ ing

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

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thi sd o cu m en

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agen lksw Vo by

9. Alignment jig

43

AG.

Prote cted by c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 8 - Mounting point for front lon‐ gitudinal member 12 - Mounting point for front locking of engine carrier 16 - Mounting point for front AG. Volkswagen AG d agen oes suspension strut ksw not l o V y db

e 20 - Mountingopoint for rear ris th locking of engine carrier u a

ht rig py Co t.

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C op yi

Rep. Gr.00 - Technical data

do c um en

44

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

ss

gu ara nte eo ra c

Jetta 2005 ➤ Body Repairs - Edition 04.2009 8 - Straightening bracket mounting point for front longi‐ tudinal member 12 - Straightening bracket mounting for front locking of engine carrier 16 - Straightening bracket mounting of front suspension strut 20 - Straightening bracket mounting for rear locking of en‐ gine carrier

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

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thi sd o cu m en

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22 - Compensation sleeve when assembly is removed

9. Alignment jig

45

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Jetta 2005 ➤ olkswagen AG en AG. V does wag04.2009 Body Repairs - Edition no olks

Centre alignment bracket

ility ab y li an pt ce

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9.3

t gu ara nte eo ra c

yV db ise r tho au s s

28 - Mounting point of rear lon‐ gitudinal member

AG.

Prote cted by

Rep. Gr.00 - Technical data

agen lksw Vo by

c o p yri gh t.

C op yi

46

ht rig py Co t.

r fo ng

30 - Mounting point of axle sus‐ pension

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

26 - Side member support point

Jetta 2005 ➤ Body Repairs - Edition 04.2009 26 - AB mounting for side member 28 - Straightening bracket mounting for rear longitudinal member 30 - Straightening bracket mounting for axle suspension

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

do c um en

9. Alignment jig

47

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

50 - Mounting point for rear longitudinal member

Prote cted by c o py rig ht .

C op yi

Rep. Gr.00 - Technical data

thi sd o cu m en

48

rrectness of i t to the co nf o r m spec atio h re n in wit

40 - Mounting point for rear locking of rear suspension

AG.

36 - Mounting point of rear sus‐ pension strut

ility ab y li an pt ce

34 - Mounting point for front locking of rear suspension

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Rear alignment bracket

agen lksw Vo by

9.4

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009 34 - Straightening bracket mounting for front locking of rear mounting 36 - Straightening bracket mounting for rear suspension strut 40 - Straightening bracket mounting for rear locking of rear mounting 50 - Straightening bracket mounting for rear longitudinal member

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

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thi sd o cu m en

9. Alignment jig

49

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

10

Portal gauge

10.1

Overview

Special tools and workshop equipment required ♦ Alignment bracket set for Touran -VAS 6240♦ Alignment bracket set supplement for Golf 2004 ▸ -VAS 6240/2♦ Alignment bracket set supplement for Jetta 2005 ▸/Bora 2006 ▸ -VAS 6240/5n AG. Volkswagen AG do es n ot g ua ran tee or a -VAS 5007/25- , front door aperture c

ge ♦ Portal gauge -VASolk5007/25swa

yV db

e ris Front door aperture tho

rrectness of i t to the co nform spec at i h re o n wit in t his do c um en

AG.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

agen lksw Vo by

au

Set up forssportal gauge

ht rig py Co t.

10.1.1

Prote cted by c o py rig ht .

C op yi

Detailed information on setting up the alignment bracket set can be found with the equipment.

50

Rep. Gr.00 - Technical data

Jetta 2005 ➤ Body Repairs - Edition 04.2009

10.1.2

Rear door aperture

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

Set up for portal gauge -VAS 5007/25- , front door aperture

do c um en

ht rig py Co t.

r te o iva r rp fo g n

Detailed information on setting up the alignment bracket set can be found with the equipment.

10. Portal gauge

51

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

50 –

Body - front

RO: 50 40 55 50

1

agen AG n AG. Vo bracket does Renewing right-hand wage no olks

lksw

t gu ara nte eo ra c

Removing

Rep. Gr.50 - Body - front

AG.

52

agen lksw Vo by

Prote cted by c o p yri gh t.

C op yi

– Release original joint.

ht rig py Co t.

1.1

rrectness of i t to the co nf o r m spec atio h re n in wit

⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

thi sd o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Observe safety notes!

ility ab y li an pt ce

yV db ise r WARNING tho au s s

Jetta 2005 ➤

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

kswageRepairs n AG d AG. VolBody - Edition 04.2009 agen oes ksw not l o V gu y ara db e nte is r o eo h ut ra a c s s

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht .

C op yi

– Remove remaining material.

1.2

Installing

1.2.1

Welding in

Replacement part ♦ Right engine bracket – Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

1. Renewing right-hand bracket

53

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

r fo ng

AG.

Prote cted by

Rep. Gr.50 - Body - front

agen lksw Vo by

c o p yri gh t .

C op yi

54

ht rig py Co t.

– Weld in console, RP spot weld seam

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 40 55 56

2

Renewing left console

WARNING

Observe safety notes!

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

do c um en

ht rig py Co t.

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

2. Renewing left console

55

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Removing

AG.

Prote cted by

Rep. Gr.50 - Body - front

agen lksw Vo by

c o p yri gh t.

C op yi

– Remove remaining material.

rrectness of i t to the co nf o r m spec atio h re n in wit

– Release original joint.

thi sd o cu m en

– Release original joint.

56

ility ab y li an pt ce

2.1

ht rig py Co t.

Jetta 2005 ➤ Body Repairs -

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t Edition 04.2009 u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

2.2

Installing

2.2.1

Preparing new part

Replacement part ♦ Left engine console – Drill 7 mm ∅ holes for SG plug weld seam.

2.2.2

Welding in

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

rrectness of i t to the co nform spec at i h re o n wit in t his

– Weld in engine console, SG plug weld seam and RP spot weld seam.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

2. Renewing left console

57

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 43 55 00

3

Renewing retaining bracket (for subframe)

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Note

The description of the procedure for renewing the front left re‐ taining bracket uses this vehicle as an example. The procedure, as appropriate, should be used for the other 3 retaining brackets.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

AG.

Prote cted by

Rep. Gr.50 - Body - front

agen lksw Vo by

c o p yri gh t .

C op yi

58

do c um en

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

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ility ab y li an pt ce

un le

Removing

ht rig py Co t.

3.1

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Release original joint.

– Remove remaining material.

3.2

Installing

3.2.1

Preparing new part

n AG. Volkswagen AG do es n wage s k l ot g o Replacement part yV ua b ra ed s i r for subframe (spare part designation: ntee ♦ Front retaining bracket o h t or u retaining brackets asubframe) ac s

Welding in

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

rrectness of i t to the co nform spec at i h re o n wit in t his

3.2.2

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

– Drill holes for SG plug weld seam.

3. Renewing retaining bracket

59

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

Jetta 2005 ➤ Body Repairs - Edition 04.2009

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

Rep. Gr.50 - Body - front

ht rig py Co t.

60

do c um en

r te o iva r rp fo g n

– Weld in new part, SG plug weld seam.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 65 55 00

4

Renewing front bumper bracket

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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Removing

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– Release original joint.

4. Renewing front bumper bracket

61

Jetta 2005 ➤ Body Repairs - Edition 04.2009

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Welding in

Prote cted by

4.2.1

Replacement part ♦ Front bumper bracket – Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

62

Rep. Gr.50 - Body - front

AG.

Installing

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c o p yri gh t.

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4.2

ht rig py Co t.

– Remove remaining material.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

– Release original joint.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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– Release original joint.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld front bumper bracket, SG continuous weld seam.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

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– Weld front bumper bracket, SG continuous weld seam.

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4. Renewing front bumper bracket

63

AG.

Prote cted by c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 72 55 00

5

Renewing upper wheel housing lon‐ gitudinal member

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions 1 - Upper longitudinal member for wheel housing 2 - Wheel housing

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Rep. Gr.50 - Body - front

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64

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3 - Longitudinal member

Jetta 2005 ➤ Body Repairs - Edition 04.2009

5.1

Removing

– Release original joint.

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– Release original joint.

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– Remove remaining material.

AG.

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Preparing new part

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5.2.1

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Installing

do c um en

5.2

Replacement part ♦ Upper inner wheel housing longitudinal member ♦ Upper outer wheel housing longitudinal member ♦ 2K body adhesive -D 180 KD3 A2– Drill holes for SG plug weld seam.

5.2.2

Welding in

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

– Check fit with add on parts.

5. Renewing upper wheel housing longitudinal member

65

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld longitudinal member for upper inner wheel housing, SG plug weld seam.

Note

New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.

– Apply 2-K body adhesive -D 180 KD3 A2- in the area of the factory bonding.

r fo ng

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Rep. Gr.50 - Body - front

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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66

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–

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise Weld longitudinal member fororupper outer wheel housing, SG eo h t weld seam. plug weld seam and RP spot u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 72 55 02

6

Renewing upper longitudinal mem‐ ber for wheel housing - partial renew‐ al

WARNING

Observe safety notes!

AG. Volkswagen AG d agen oes

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6.1

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3 - Longitudinal member

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2 - Wheel housing

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1 - Upper longitudinal member for wheel housing

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Removing

– Make parting cut on outer longitudinal member as shown.

6. Renewing upper longitudinal member for wheel housing - partial renewal

67

Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 170 mm – Release original joint.

– Make parting cut on inner longitudinal member.

Preparing new part

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Replacement part ♦ Upper inner wheel housing longitudinal member ♦ Upper outer wheel housing longitudinal member ♦ 2K body adhesive -D 180 KD3 A2-

68

Rep. Gr.50 - Body - front

AG.

6.2.1

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Installing

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6.2

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– Remove remaining material.

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– Release original joint.

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Jetta 2005 ➤ - Edition 04.2009

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Welding in Prote cted by c o py rig ht .

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– Check fit with add on parts.

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– Weld longitudinal member for upper inner wheel housing, RP spot weld seam.

AG.

– Weld parting cut, SG stepped weld seam.

ht rig py Co t.

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

thi sd o cu m en

6.2.2

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– Transfer parting cuts

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– Apply 2-K body adhesive -D 180 KD3 A2- in the area of the factory bonding.

Note

New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.

– Removing and installing upper outer longitudinal member for wheel housing – Weld in upper outer longitudinal member for wheel housing, RP spot weld seam.

– Weld in parting cut, SG stepped weld seam.

6. Renewing upper longitudinal member for wheel housing - partial renewal

69

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 74 55 50

7

Renewing front wheel housing

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

7.1 •

Removing

Upper longitudinal member for wheel housing already re‐ moved ⇒ “5 Renewing upper wheel housing longitudinal member”, page 64 .

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Rep. Gr.50 - Body - front

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70

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– Remove remaining material.

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– Release original joint.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

7.2

Installing

7.2.1

Preparing new part

Replacement part ♦ Wheel housing

7.2.2

Welding in

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

– Check fitting to adjacent components.

– Weld in wheel housing, SG plug weld seam and RP spot weld seam.

– Install upper longitudinal member for wheel housing ⇒ “5.2 Installing”, page 65 .

rrectness of i t to the co nform spec at i h re o n wit in t his

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7. Renewing front wheel housing

71

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 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 Note

The thread repair is described for the front left retaining bracket for the subframe on this vehicle and the procedure, as appropri‐ ate, should be used for the other 3 retaining brackets.

Special tools and workshop equipment required ♦ Thread repair kit M12x1.5 -VAS 6058♦ Drill -VAS 62671 - Threaded plate (welded to AG. Volkswagen AG do agen subframe retaining bracket) es n lksw

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Rep. Gr.50 - Body - front

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72

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 2 - Helicoil thread insert

8.1

Contents of thread repair kit

1 - Twist drill ∅ 12.5 mm 2 - Thread-cutting tap M12 x 1.5 3 - Fitting spindle 4 - Thread insert M12 x 1.5 x 24 ( -VAS 6058/1- ) 5 - Pin breaker with magnetic end

rrectness of i t to the co nform spec at i h re o n wit in t his

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8. Repairing threads for securing subframe (suspension subframe)

73

AG.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.2

Repairing thread

8.2.1

Drilling thread

– Drill thread with a twist drill.

Note

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support when drilling.

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♦

♦ Do not cant the drill.

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Rep. Gr.50 - Body - front

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♦

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Use drill -VAS 6267- when drilling isand ed shaping. nte r o eo h ut ra The drill must be held by an assistant using an additional hand a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.2.2

Cutting thread

– Cut thread with a thread tap.

– Clean threaded sleeve (blow out with compressed air).

8.2.3

Inserting thread insert

– Fit threaded mounting -3- on assembly spindle until the drive pin -2- on the drive lug -1- lies against the assembly spindle.

Note

Thread insert must screw in easily.

rrectness of i t to the co nform spec at i h re o n wit in t his

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8. Repairing threads for securing subframe (suspension subframe)

75

AG.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Turn threaded mounting into the threaded plate until the threa‐ ded mounting is flush with the threaded plate from the exterior (visual check).

– Then turn threaded mounting 1/4 turn further inwards.

– Unscrew fitting spindle.

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Rep. Gr.50 - Body - front

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76

do c um en

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– Install subframe (suspension subframe) (torque settings) ⇒ Suspension, axles, steering; Rep. Gr. 40 ; Removing and in‐ stalling subframe, torque settings

ht rig py Co t.

– Break drive pin of threaded

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a mounting off using pin breaker. c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 79 55 03

9

Renewing front longitudinal member

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

2 - Longitudinal member un le

pe rm itte d

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Note

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3 - Make parting cut on longi‐ tudinal member and cover plate.

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1 - Wheel housing

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

9. Renewing front longitudinal member

77

Jetta 2005 ➤ Body Repairs - Edition 04.2009 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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AG.

78

agen lksw Vo by

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– Release original joint.

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Removing

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9.1

Jetta 2005 ➤ Body Repairs - Edition 04.2009

do c um en

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Note

rrectness of i t to the co nform spec at i h re o n wit in t his

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♦ Do not damage mounting for subframe -1-. ♦ Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. ♦ Make parting cuts on longitudinal member and cover plate offset by 50 mm.

– Make parting cut as shown.

9. Renewing front longitudinal member

79

Jetta 2005 ➤ n AG. Volkswagen AG do es n wage s k l ot g o Body Repairs - Edition 04.2009 yV Dimension -a- = 50 mm

ua ran tee

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Installing

Preparing new part

Replacement part

AG.

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Rep. Gr.50 - Body - front

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80

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♦ Longitudinal member

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9.2.1

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9.2

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– Remove remaining material.

or ac

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Transfer parting cut to new part and cut out. . Volkswagen AG – Drill 7 mm ∅ holes for SG plug weld seam. gen AG d

oes wa not olks gu yV b ara d e nte is r o eo th ra Adapt new part to fit and ssecure in position with vehicle stand‐ au c ing on alignment brackets set .

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–

Welding in

– Check fitting to adjacent components.

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9.2.2

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– Butt weld parting cuts on longitudinal member and cover plate all around, SG continuous weld seam.

– Recreate remaining joint, SG plug weld seam and RP spot weld seam.

9. Renewing front longitudinal member

81

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Shortening new longitudinal member with cover plate

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en

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Note

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9.2.3

The longitudinal member -2- with cover plate -1- is too long in the front area -shaded area- and must be short‐ ened to fit and weld front bumper bracket for front longitudinal member. agen lksw Vo by

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Rep. Gr.50 - Body - front

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82

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– Fit alignment bracket mounting for front longitudinal member -RW 1- using distance plate -RW 3- and hold against longitu‐ dinal member from below (see figure).

– Transfer tracing dimension plus 2 mm -a- to longitudinal mem‐ ber and the cover plate and cut off surplus material.

9. Renewing front longitudinal member

83

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Secure front bumper bracket for front longitudinal member -1- using -RW 1- and -RW 3- in front of the longitudinal member -2-. agen lksw Vo by

AG.

Note

There must be a gap of 1-2 mm between longitudinal member -2- with cover plate -3- and bumper bracket -1-.

– Install front bumper bracket for front longitudinal member ⇒ “4.2 Installing”, page 62 .

84

Rep. Gr.50 - Body - front

Jetta 2005 ➤

RO: 50 79 55 06

Renewing front longitudinal member - partial replacement es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Observe safety notes!

rrectness of i t to the co nf o r m spec atio h re n in wit

WARNING

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10

AG. Volkswagen 04.2009 does agenBody Repairs A- GEdition ksw not l o V gu y ara db nte ise r o eo h ut ra a c s s

⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

thi sd o cu m en

AG.

Dimension -a- = 50 mm

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Note

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C op yi

2 - Longitudinal member

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1 - Cover plate

10. Renewing front longitudinal member - partial replacement

85

Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note

Do not cut or weld 50 mm before or after the laser weld seam en AG. Volkswagen AG does wag -1- (shaded area). not olks

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Rep. Gr.50 - Body - front

AG.

86

agen lksw Vo by

c o p yri gh t.

C op yi

– Release original joint.

thi sd o cu m en

– Make parting cuts as shown.

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Removing

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10.1

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yV db ise r tho au s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material.

10.2

Installing

10.2.1

Preparing new part es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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Replacement part

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

♦ Longitudinal member (subpart)

♦ Cover plate for longitudinal member

Welding in

c o p yri gh t.

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– Check fitting to adjacent components.

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– Weld longitudinal member parting cut all around, SG continu‐ ous weld seam.

do c um en

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

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10.2.2

rrectness of i t to the co nform spec at i h re o n wit in t his

– Transfer parting cuts to new parts and cut out.

Prote cted by

10. Renewing front longitudinal member - partial replacement

87

Jetta 2005 ➤ Body Repairs - Edition 04.2009

ility ab y li an pt ce

Note

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

– Recreate original joint,

AG. Volkswagen AG d agen oes ksw not l o gu RP spot weld y V seam. b ara d e nte is r o eo h ut ra a c s s

Distance between weld points -a- approx. 35-40 mm

10.2.3

rrectness of i t to the co nf o r m spec atio h re n in wit

– Weld cover plate parting cut, SG continuous weld seam.

Shortening new longitudinal member with cover plate

– Shortening longitudinal member with cover plate ⇒ “9.2.3 Shortening new longitudinal member with cover plate”, page 82 – Install front bumper bracket. ⇒ “4.2 Installing”, page 62

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Rep. Gr.50 - Body - front

thi sd o cu m en

88

Jetta 2005 ➤ Body Repairs - Edition 04.2009

51 –

Body - centre

RO: 51 03 55 00

1

Renewing roof

WARNING

Observe safety notes!

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⇒ General Information; Safety instructions

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t ra BodyauRepairs, General Body Repairs ; c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

Special tools and workshop equipment required ♦ Pneumatic cartridge gun V.A.G 1761/1♦ Cartridge heater V.A.G 1939 A-

do c um en

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♦ Double-cartridge gun VAS 5237-

1. Renewing roof

89

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AG.

Prote cted by

c o p yri gh t.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 Securing belt (commercial type)

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1.1

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Removing

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1 - Laser weld seam

Cut off roof roughly.

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– 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 damaged.

♦ Do not use cutting disks or rough grinding disks.

– Remove all adhesive residues and remaining sealing com‐ pound from the front and rear roof cross members and the roof reinforcement.

– Restore paint structure.

1.2

Installing

1.2.1

Preparing new part

Replacement part ♦ Roof ♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges)

1. Renewing roof

91

Jetta 2005 ➤ Body Repairs - Edition 04.2009 ♦ 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 BNote ♦ Following repair sequence must be adhered to in order to en‐ n AG. Volkswagen AG do sure correct and long-lasting roof repairs. e wage ks Vol

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by ♦ No filler should be applied to the ed bonding areas before the roof

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– Grind back bonding area -1- on left and right of roof to bare metal.

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Rep. Gr.51 - Body - centre

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92

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This ensures that 2K body adhesive -D 180 KD3 A2- bonds well with bonding area.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– As required, place approx. 6-10 felt pads -1- on roof frame on left and right-hand side.

– Place roof on roof frame and check position of roof relative to roof side elements is correct (visual inspection).

Note

Check that roof is aligned correctly with the rear window and the windscreen.

1. Renewing roof

93

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

– Tension two securing belts (commercially available) across roof.

– Align front belt -arrow- with marking -1- in front door openings used for fitting front roof-top carrier system bars.

– On both sides of vehicle, measure dimension -a- from marking -arrow- used for fitting front roof-top carrier system bars to‐ wards rear and then mark this point on vehicle.

Dimension -a- = 691 mm

– Tighten rear belt -2- at these markings.

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Rep. Gr.51 - Body - centre

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94

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Adjusting roof depth

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By tightening and loosening the securing belts, you can determine dimension -a- to position roof deeper relative to roof side mem‐ bers. agen lksw Vo by

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Dimension -a- = 3.5 + 0.5 mm Note

The securing belts should not be tightened too much, otherwise the roof and/or roof side members could be damaged.

1. Renewing roof

95

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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– If necessary, change felt pads -3- to adjust and improve roof alignment.

– Remove roof again.

– Clean bonding areas on roof and vehicle with silicone remover -LSE 020 100 A3- .

1.2.3

Bonding roof

Note ♦ The adhesive materials must be applied very quickly. ♦ Always observe the application time (pot life). ♦ Use pneumatic or electric cartridge guns to apply the adhesive

materials.

96

Rep. Gr.51 - Body - centre

thi sd o cu m en

– Use a drill bit (∅ 3.5 mm) to check dimension -a- (drill bit -4must be able to slide between roof -2- and securing belt -1without much resistance).

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– Apply 1-K installation adhesive -D 190 MKD A3- , using the pneumatic gun -V.A.G 1761/1- , onto the front roof cross mem‐ ber -1-, the centre roof reinforcement -2- and the rear roof cross member -3- in the area of the factory bonding.

1. Renewing roof

97

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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♦ The application time (pot life) of the 2K body adhesive -D 180

KD3 A2- is approx. 20 minutes.

♦ An assistant is required for the following work.

98

Rep. Gr.51 - Body - centre

AG.

Note

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– Apply 1K assembly adhesive -D 190 MKD A3- -A- on the inner side of roof parallel to the left and right roof flange with the pneumatic gun -V.A.G 1761/1- .

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– Apply 1K assembly adhesive -D 190 MKD A3- -A- in area of roof member, using pneumatic cartridge gun -V.A.G 1761/1- .

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Cut the first step of the static mixer -D- off to achieve the cor‐ responding bead cross-section.

– Carefully operate the double cartridge gun -VAS 5237- 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 adhesive to a piece of cardboard and only then begin to apply the adhesive to the vehicle.

– Now fill area -C- with 2K body adhesive -D 180 KD3 A2- using double-cartridge gun -VAS 5237- .

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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– Lightly coat the roof flanges -1- with 2K body adhesive -D 180 KD3 A2- .

– Place roof in position immediately and align.

– Secure roof to front window opening and rear lid opening using mole grips, and to centre section using securing belts.

– Remove excessive adhesive at side of roof immediately using a cloth soaked in silicone remover -LSE 020 100 A3- .

1. Renewing roof

99

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ 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 to harden (hardening time).

♦ No further work should be performed on the vehicle until the

“hardening time” has expired.

1.2.4

Welding in

Prote cted by

– Apply adhesive sealant -AKD 476 KD5 05- from above to fully seal off bonding seam -1-.

100

Rep. Gr.51 - Body - centre

AG.

– Prime left and right-hand roof frame from inside with primer ALN 002 003 04- .

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– Weld roof to rear window aperture, RP spot weld seam.

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– Weld roof to windscreen aperture, RP spot weld seam.

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Note

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– Check roof depth dimension -a- for the roof ⇒ “1.2.2 Adjusting roof depth”, page 95

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– After painting, treat roof cavities -arrow- with cavity sealant AKR 321 M15 4- .

Jetta 2005 ➤ Repairs - Edition 04.2009

ility ab y li an pt ce

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1. Renewing roof

101

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 07 55 50

2

Renewing front roof cross member

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

2.1

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Rep. Gr.51 - Body - centre

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102

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– Release original joint.

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Roof already removed ⇒ “1 Renewing roof”, page 89 .

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Removing

Jetta 2005 ➤ Body Repairs - Edition 04.2009

pe rm itte d

2.2.1

Installing

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2.2

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– Remove residues at transition to left and right roof frame.

Welding in

Replacement part ♦ Front roof cross member – Fit new part and secure.

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– Check that roof is aligned correctly to the windscreen.

2. Renewing front roof cross member

103

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in front roof cross member, SG continuous weld seam and RP spot weld seam.

– Install roof ⇒ “1.2 Installing”, page 91 .

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Rep. Gr.51 - Body - centre

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104

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 08 55 50

3

Renewing roof reinforcement

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

3.1 •

Removing

Roof already removed ⇒ “1 Renewing roof”, page 89 .

rrectness of i t to the co nform spec at i h re o n wit in t his

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– Release original joint.

3. Renewing roof reinforcement

105

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove residues on left and right roof frame.

3.2.1

Welding in

Replacement part ♦ Roof reinforcement

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Installing

rrectness of i t to the co nform spec at i h re o n wit in t his

3.2

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– Adapt roof reinforcement and secure.

– Check fitting to roof.

AG.

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Rep. Gr.51 - Body - centre

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106

ht rig py Co t.

– Install roof ⇒ “1.2 Installing”, page 91 .

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– Weld roof reinforcement to left and right roof frame, SG con‐ tinuous weld seam.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 09 55 50

4

Renewing rear roof cross member

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

4.1 •

Removing

Roof already removed ⇒ “1 Renewing roof”, page 89 .

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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– Release original joint from interior.

4. Renewing rear roof cross member

107

ht rig py Co t.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove residues at transition to left and right roof frame.

Installing

4.2.1

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Welding in

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– Check that roof is aligned correctly to the rear window.

AG.

Rep. Gr.51 - Body - centre

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108

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– Fit new part and secure.

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♦ Rear roof cross member

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4.2

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– Weld in new part, SG continuous weld seam (staggered).

– Install roof ⇒ “1.2 Installing”, page 91 .

4. Renewing rear roof cross member

109

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 37 55 00

WARNING

rrectness of i t to the co nf o r m spec atio h re n in wit

Observe safety notes!

Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment. Therefore, refrain from using these processes. ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

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Rep. Gr.51 - Body - centre

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110

thi sd o cu m en

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Renewing A-pillar - partial renewal

ility ab y li an pt ce

5

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Upper parting cut 2 - Moulded foam element Dimension -a- = 195 mm Note 3 - Parting cut for side member Note

rrectness of i t to the co nf o r m spec atio h re n in wit

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4 - Bonded section

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5. Renewing A-pillar - partial renewal

111

Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Make parting cuts -1- according to damage.

– Release original joint.

– Remove remaining material.

112

Rep. Gr.51 - Body - centre

AG.

Make parting cuts with pneumatic jig-saw -V.A.G 1523- only.

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Note

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Removing

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5.1

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove adhesive remains completely and grind adhesive surfaces back to bare metal.

5.2 5.2.1

Installing AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Preparing new part

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Replacement part

♦ A-pillar subpart with side member sealing plate ♦ Moulded foam element

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ 2K body adhesive -D 180 KD3 A2– Transfer parting cuts to the new part and cut.

– Drill 7 mm ∅ holes for SG plug weld seam.

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5.2.2

Moulded foam elements

Follow repair instructions.

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

5. Renewing A-pillar - partial renewal

113

Jetta 2005 ➤ Body Repairs - Edition 04.2009

5.2.3

Welding in . Volkswagen AG

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Note

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does not gu ara nte eo ra c

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New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

– Check fit with add on parts.

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Rep. Gr.51 - Body - centre

thi sd o cu m en

114

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld parting cuts and connecting area to reinforcement for lower side member, SG stepped weld seam.

– Recreate original joint in windscreen and door apertures, RP spot weld seam.

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ot g olks – Weld seam to reinforce A-pillar, SG plug weld nseam yV ua and SG d b seam (staggered). ran e continuous rweld is t

5. Renewing A-pillar - partial renewal

115

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 38 55 50

Renewing A-pillar reinforcement pe rm itte d

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WARNING

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Observe safety notes!

Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment. Therefore, refrain from using these processes. ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

A-pillar already removed ⇒ “5 Renewing A-pillar - partial renewal”, page 110 r te o iva r rp fo g n

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Rep. Gr.51 - Body - centre

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116

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Upper longitudinal member cover plate for wheel housing al‐ ready removed ⇒ “5 Renewing upper wheel housing longitudinal member”, page 64 .

do c um en

•

Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - A-pillar reinforcement 2 - Front side member rein‐ forcement 3 - Moulded foam element Note

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4 - Upper longitudinal member cover plate for wheel housing

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6. Renewing A-pillar reinforcement

117

Prote cted by c o p yri gh t.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

6.1

Removing

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

– Separate original joint of A-pillar reinforcement.

– Separate bead of upper hinge reinforcement from interior.

ht rig py Co t.

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AG.

Prote cted by c o p yri gh t.

C op yi

Rep. Gr.51 - Body - centre

thi sd o cu m en

118

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material.

6.2

Installing

6.2.1

Preparing new part

Replacement part ♦ A-pillar reinforcement with web plate for side member ♦ Moulded foam element ♦ 2K body adhesive -D 180 KD3 A2-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

6.2.2

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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– Drill 7 mm ∅ holes for SG plug weld seam.

Moulded foam elements

Follow repair instructions.

do c um en

ht rig py Co t.

r te o iva r rp fo g n

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

6. Renewing A-pillar reinforcement

119

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AG.

Prote cted by c o py rig ht .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

6.2.3

Welding in

ility ab y li an pt ce

Note

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

– Apply 2-K body adhesive -D 180 KD3 A2- in door aperture.

n AG. Volkswagen AG do es n wage s k l ot g Vo the area dof ua by the ran ir se tee o h t or u ac a ss

rrectness of i t to the co nf o r m spec atio h re n in wit

New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Rep. Gr.51 - Body - centre

thi sd o cu m en

120

ht rig py Co t.

– Check fitting to A-pillar.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in A-pillar reinforcement, SG plug weld seam and RP spot weld seam.

– Weld in A-pillar reinforcement from interior, SG plug weld seam.

– Install upper longitudinal member cover plate for wheel hous‐ ing ⇒ “5.2 Installing”, page 65 .

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

do c um en

ht rig py Co t.

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

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– Install A-pillar ⇒ “5.2 Installing”, page 113 .

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6. Renewing A-pillar reinforcement

121

AG.

Prote cted by

c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 41 55 00

7

Renewing B-pillar

DANGER!

Observe safety notes!

Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment. Therefore, refrain from using these processes.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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AG.

Prote cted by

c o p yri gh t.

C op yi

Rep. Gr.51 - Body - centre

ht rig py Co t.

122

do c um en

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Bonded section 2 - Side panel 3 - Moulded foam element Note 4 - Side member 5 - Outer B-pillar

do c um en

ht rig py Co t.

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AG.

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C op yi

Upper B-pillar cut lines

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

7. Renewing B-pillar

123

Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Outer B-pillar 2 - B-pillar reinforcement

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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AG.

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Rep. Gr.51 - Body - centre

ht rig py Co t.

124

do c um en

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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3 - Inner B-pillar

Jetta 2005 ➤ Body Repairs - Edition 04.2009

7.1

Removing

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

♦ 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 of the side member (parting cut -3-,

430 mm from the front edge of the side member) and the area -5- must be cut out at the same time.

♦ When doing this do not damage original joint to roof.

– Make parting cut -1- as shown.

do c um en

Dimension -a- = 100 mm

– When making parting cut -2-, keep cutting/overlap of replace‐ ment part in mind. ht rig py Co t.

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– Make parting cut -3- on side member according to damage. agen lksw Vo by

AG.

– Release original joint.

7. Renewing B-pillar

125

Jetta 2005 ➤ Body Repairs - Edition 04.2009 Partial renewal

A part renewal of the B-pillar without damage to the side member is possible using parting cut -4-.

– Release original joint to side member reinforcement.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht .

C op yi

Rep. Gr.51 - Body - centre

do c um en

126

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material.

– Remove adhesive remains completely and grind adhesive surfaces back to bare metal.

– Clean flange area of wheel arch so that it is free of dust and grease.

7.2

Installing

7.2.1

Preparing new part

Replacement part ♦ B-pillar subpart ♦ Moulded foam element ♦ 2K body adhesive -D 180 KD3 A2– Transfer parting cuts to the new part and cut.

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

agen lksw Vo by

7. Renewing B-pillar

127

AG.

Prote cted by c o py rig ht .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Marking area where no welding work may be carried out

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

r fo ng

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

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7.2.2

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AG.

Prote cted by c o py rig ht .

C op yi

Note ♦ When welding in B-pillar, welding work must not be carried out in the areas marked on the illustrations for

“crash safety” reasons.

♦ The measurements given must be adhered to.

– Mark areas on outer B-pillar in which no welding may be car‐ ried out. ♦ Dimension -a- = 45 mm ♦ Dimension -b- = 145 mm

7.2.3

Moulded foam elements

Follow repair instructions.

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

128

Rep. Gr.51 - Body - centre

Welding in

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– Place

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or backing plate behind side panel parting cut. u ac a ss

do c um en

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7.2.4

Jetta 2005 ➤ Body Repairs - Edition 04.2009

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

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Note ♦ Holes for door hinges in area -1- must remain free of adhesive. ♦ New part must be welded within 20 minutes, otherwise adhesive properties of adhesive will be impaired.

– In area -1- apply 2-K body adhesive -D 180 KD3 A2- (flat, sev‐ eral beads, ∅ 3.5 mm).

– In area -2- apply 2-K body adhesive -D 180 KD3 A2- (1 bead, ∅ 3.5 mm).

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

– Check fit with add on parts.

7. Renewing B-pillar

129

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Note that no welding work may be carried out in areas -1-.

– Weld in B-pillar, RP spot weld seam.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Rep. Gr.51 - Body - centre

ht rig py Co t.

130

do c um en

r te o iva r rp fo g n

– Weld in parting cut, SG stepped weld seam.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Establish remaining joint side member reinforcement, SG stepped weld seam.

– Bead over wheel arch flange.

– Wipe leaking adhesive off and seal wheel housing.

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

agen lksw Vo by

7. Renewing B-pillar

131

AG.

Prote cted by c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 42 55 50

8

Renewing B-pillar reinforcement

DANGER!

Observe safety notes!

Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment. Therefore, refrain from using these processes. ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

r fo ng

AG.

Prote cted by

Rep. Gr.51 - Body - centre

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c o p yri gh t .

C op yi

132

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

Outer B-pillar already removed ⇒ “7 Renewing B-pillar”, page 122

ht rig py Co t.

•

Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Cutting point 2 - Rear side member rein‐ forcement 3 - Moulded foam element Note 4 - Front side member rein‐ forcement 5 - B-pillar reinforcement

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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r fo ng

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

Note

8. Renewing B-pillar reinforcement

133

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t.

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.1

Removing

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t.

C op yi

Note ♦ B-pillar reinforcement must only be cut at the point indicated -1-. ♦ Cutting or welding at a point other than the one shown is impermissible due to safety reasons “crash safety”. ♦ Do not damage roof frame reinforcement.

– Make parting cut -1- in roof compound as shown. To do this, a part of the roof frame must also be cut out and renewed as shown, when the outer B-pillar is cut out.

– Release original joint to roof member.

134

Rep. Gr.51 - Body - centre

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

Jetta 2005 ➤ Body Repairs - Edition 04.2009

agen lksw Vo by

AG.

Prote cted by c o py rig ht .

C op yi

– Make parting cuts as shown (each before -1- or behind -2- the inner bulkheads).

– Release original joint to inner side member.

8. Renewing B-pillar reinforcement

135

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Prote cted by

136

Rep. Gr.51 - Body - centre

AG.

– Remove remaining material.

agen lksw Vo by

c o p yri gh t.

C op yi

If the inner B-pillar is damaged excessively, then it must also be renewed.

ht rig py Co t.

Note

do c um en

– Separate remaining joint in door apertures.

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.2

Installing

8.2.1

Preparing new part

Replacement part ♦ B-pillar reinforcement ♦ Front side member reinforcement ♦ Rear side member reinforcement ♦ Moulded foam element ♦ 2K body adhesive -D 180 KD3 A2-

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

thi sd o cu m en

ht rig py Co t.

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AG.

Prote cted by c o py rig ht .

C op yi

– Transfer parting cuts to the new parts and cut.

Note

Use plug weld drill for “BTR steels” when drilling holes for SG plug weld seam . HSS drills are not suitable as they do not have the required durability.

– Drill holes for SG plug weld seam.

8. Renewing B-pillar reinforcement

137

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

r te o iva r rp fo g n

♦ The side member reinforcement and the B-pillar reinforcement may only be joined from above and below

do c um en

as shown in the -enlargements-, otherwise the strength of the B-pillar will be adversely affected. 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‐ ht rig py Co t.

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C op yi

forcement. This illustration is basically the same as for the B-pillar reinforcement area and the rear side member reinforcement.

– Tack-weld side member front reinforcement -1- to B-pillar re‐ inforcement -3- from above -2- and below -5-, SG continuous weld (2 x tack welds each a max length of 10 mm).

– Tack-weld side member front reinforcement -4- to B-pillar re‐ inforcement -3- from above -2- and below -5-, SG continuous weld (2 x tack welds each a max length of 10 mm).

– Remove new part from vehicle.

138

Rep. Gr.51 - Body - centre

AG.

– Check fit with B-pillar.

agen lksw Vo by

– Adapt new parts with vehicle standing on its wheels or on alignment bracket set and fix in position.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t.

C op yi

– Weld side member front reinforcement -3- to B-pillar reinforce‐ ment -2-, RP spot welds (2 x spot welds on each upper and lower sides and 8 x spot welds in two rows on outer side).

– Weld side member rear reinforcement -1- to B-pillar reinforce‐ ment -2- from interior, SG plug weld seam.

8. Renewing B-pillar reinforcement

139

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Marking areas where no welding work may be carried out

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Note

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

8.2.2

♦ 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 measurements given must be adhered to.

– Marking the areas where no welding work may be carried out

Follow repair instructions.

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

140

Rep. Gr.51 - Body - centre

AG.

Moulded foam elements

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8.2.3

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C op yi

♦ Dimension -b- = 145 mm

ht rig py Co t.

♦ Dimension -a- = 45 mm

do c um en

r te o iva r rp fo g n

♦ Transfer dimensions to outer B-pillar before welding in outer B-pillar.

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.2.4

Welding in

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

thi sd o cu m en

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Note

Prote cted by c o p yri gh t.

C op yi

New part must be welded-in within 20 minutes or adhesion properties of adhesive will be impaired. agen lksw Vo by

– In area -1- apply 2-K body adhesive -D 180 KD3 A2- (1 bead, ∅ 3.5 mm).

AG.

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

– Check fitting to B-pillar and attachments.

8. Renewing B-pillar reinforcement

141

Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG.

Rep. Gr.51 - Body - centre

agen lksw Vo by

Prote cted by c o p yri gh t.

C op yi

142

ht rig py Co t.

– Weld upper B-pillar reinforcement, SG plug weld seam.

do c um en

– Weld upper part of parting cut of B-pillar reinforcement, SG continuous weld seam.

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

do c um en

ht rig py Co t.

r te o iva r rp fo g n

– Weld front -1- and rear -2- parting cuts, SG stepped weld seam.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8. Renewing B-pillar reinforcement

143

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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AG.

Prote cted by

c o p yri gh t.

C op yi

– Recreate remaining joint, RP spot weld seam.

– Install outer B-pillar ⇒ “7.2 Installing”, page 127 .

144

Rep. Gr.51 - Body - centre

ht rig py Co t.

Note that no welding work may be carried out in areas -1-.

do c um en

Note

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 45 55 00

9

Renewing side member

WARNING

Observe safety notes!

Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment. Therefore, refrain from using these processes.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

do c um en

ht rig py Co t.

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

9. Renewing side member

145

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t .

C op yi

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

Prote cted by

c o p yri gh t .

C op yi

Rep. Gr.51 - Body - centre

thi sd o cu m en

146

AG.

Note

ility ab y li an pt ce

2 - Moulded foam elements

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1 - Bonded section

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ht rig py Co t.

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

9.1

Removing

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Note

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♦ Make parting cuts with pneumatic jig-saw -V.A.G 1523- only.

♦ When making parting cut -3-, keep cutting/overlap of replacement part in mind. ht rig py Co t.

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– Make parting cut -1- on A-pillar according to damage.

– Make parting cut -2- over the mounting of the lower door hinge of the rear door.

AG.

– Make parting cut -3-.

– Grind through outer edge on wheel arch.

– Release original joint.

9. Renewing side member

147

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Release original joint to side member reinforcement.

rrectness of i t to the co nf o r m spec atio h re n in wit

– Remove remaining material.

– Remove remaining adhesive completely and grind bonded surface back to bare metal.

– Clean flange area of wheel arch so that it is free of dust and grease.

Preparing new part

Prote cted by

♦ Side member with cover plate subpart ♦ Moulded foam element ♦ 2K body adhesive -D 180 KD3 A2-

148

Rep. Gr.51 - Body - centre

AG.

Replacement part

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9.2.1

Installing

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9.2

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Transfer parting cut to new part and cut out.

– Apply 2-K body adhesive -D 180 KD3 A2- on adhesive area of the side member end piece -1- -2-, fit into side member -3- and weld in with RP spot weld seam.

9.2.2

Moulded foam elements

Follow repair instructions.

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

9. Renewing side member

149

Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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Note

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Marking area where no welding work may be carried out

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9.2.3

♦ When welding in side member, welding work must not be carried out in areas marked on the illustrations for

“crash safety” reasons.

♦ The measurements given must be adhered to.

– Mark the areas on the outer side member where no welding work may be carried out. ♦ Dimension -a- = 45 mm ♦ Dimension -b- = 145 mm

9.2.4

Welding in

– Place backing plate behind side member/side panel parting cut.

150

Rep. Gr.51 - Body - centre

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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AG.

Prote cted by c o p yri gh t.

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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 adhesive will be impaired.

– In area -1- apply 2-K body adhesive -D 180 KD3 A2- (1 bead, ∅ 3.5 mm).

– In area -2- apply 2-K body adhesive -D 180 KD3 A2- (flat, sev‐ eral beads, ∅ 3.5 mm).

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

– Check fit with add on parts.

9. Renewing side member

151

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Note that no welding work may be carried out in areas -1-.

– Butt weld parting cuts of A-pillar and B-pillar, SG stepped weld seam. r te o iva r rp fo g n

Rep. Gr.51 - Body - centre

AG.

152

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– Recreate original joint, RP spot weld seam.

ht rig py Co t.

– Weld end piece and front side member with A-pillar reinforce‐ ment, SG plug weld seam.

do c um en

– Weld parting cut of side member to side panel, SG stepped weld seam.

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Recreate remaining joint side member reinforcement, SG stepped weld seam.

– Bead over wheel arch flange.

– Wipe away excess adhesive and seal wheel arch.

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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9. Renewing side member

153

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Renewing side member reinforce‐ ment

rrectness of i t to the co nform spec at i h re o n wit in t his

(front)

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Side member already removed ⇒ “9 Renewing side member”, page 145

AG.

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Rep. Gr.51 - Body - centre

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154

ht rig py Co t.

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10

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RO: 51 49 55 50

e ris tho u a ss

Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte se i r 2 - Side member reinforcement o eo h t u ra a c s s 3 - A-pillar

1 - B-pillar reinforcement

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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10. Renewing side member reinforcement

155

AG.

Prote cted by

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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10.1

– Make parting cut as shown (in front of the inner bulkhead).

– Release original joint.

AG.

Rep. Gr.51 - Body - centre

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156

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r te o iva r rp fo g n

– Remove remaining material.

ht rig py Co t.

Dimension -a- = 300 mm

Jetta 2005 ➤ Body Repairs - Edition 04.2009

10.2

Installing

10.2.1

Preparing new part

Replacement part

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Transfer parting cut to new part and cut it.

AG.

– Fit new part and secure.

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Welding in

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10.2.2

ht rig py Co t.

– Drill holes for SG plug weld seam as shown, ∅ 10 mm.

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r te o iva r rp fo g n

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es, in part or in w l purpos hole ercia , is n m ot com

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♦ Front side member reinforcement

– Check fitting to adjacent components.

10. Renewing side member reinforcement

157

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

pe rm itte d

– Weld original joint, SG plug weld seam and RP spot weld seam.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Weld connection to web plate, SG plug weld seam.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

– Weld parting cut, SG continuous weld seam.

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AG.

Prote cted by

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Rep. Gr.51 - Body - centre

ht rig py Co t.

158

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– Install side member ⇒ “9.2 Installing”, page 148 .

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 49 55 52

11

Renewing side member reinforce‐ ment (rear)

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Side member already removed ⇒ “9 Renewing side member”, page 145

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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•

11. Renewing side member reinforcement

159

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing

1 - Inner side panel un le

Make parting cut as shown (behind the inner bulkhead).

–

Separate original joint to inner side member, to inner side panel and to wheel housing liner.

r fo ng

–

Installing

11.2.1

Preparing new part

Replacement part ♦ Rear side member reinforcement

160

Rep. Gr.51 - Body - centre

AG.

11.2

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– Remove material remains on inner side member and on outer wheel housing liner.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

3 - Cutting point

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2 - Wheel housing liner

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

11.1

Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Transfer parting cut to new part and cut it.

11.2.2

Welding in

– Fit new part and secure.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

do c um en

ht rig py Co t.

r te o iva r rp fo g n

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– Check fitting to adjacent components.

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– Weld in rear side member reinforcement, RP spot weld seam.

– Weld parting cut, SG stepped weld seam.

– Install side member ⇒ “9.2 Installing”, page 148 .

11. Renewing side member reinforcement

161

Jetta 2005 ➤ Body Repairs - Edition 04.2009 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

♦ If

un le

aged, the component must be replaced. pe rm itte d

♦ The vehicle identification number is located on the right side es, in part or in w l purpos hole ercia , is n m ot com

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Rep. Gr.51 - Body - centre

do c um en

162

rrectness of i t to the co nform spec a t i h re o n in wit thi s

of the vehicle. If this mounting has to be replaced during ac‐ cident damage repair, an impartial expert is to be consulted (reference chassis number) prior to the work being carried out.

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12.1

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing Note

When separating laser welded seams, ensure that the panels ly‐ ing behind are not damaged.

– Cut out seat cross member mounting.

– Release original joint.

– Remove remaining material.

12. Renewing seat cross member mounting

163

Jetta 2005 ➤ Body Repairs - Edition 04.2009

12.2

Installing

12.2.1

Preparing new part

Replacement part ♦ Seat cross member mounting – Drill 7 mm ∅ holes for SG plug weld seam.

12.2.2

Welding in

– Fit new part and secure.

– Check fit with add on parts.

– Weld in seat cross member mounting plate, SG plug weld G. Volkswagen AG d A agen oes seam. ksw not l o V

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Rep. Gr.51 - Body - centre

thi sd o cu m en

164

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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13

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RO: 51 69 55 58

AG. Volkswagen AG d agen oes ksw not Jetta 2005 ➤ l o V gu by ara d Body Repairs - Edition e nte 04.2009 is r o eo h t ra au c s s

(on Tunnel) WARNING

Observe safety notes!

rrectness of i t to the co nf o r m spec atio h re n in wit

Renewing seat cross member mounting

⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

Seat middle cross member already removed ⇒ “14 Renewing seat cross member”, page 168

agen lksw Vo by

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AG.

•

ht rig py Co t.

If a thread in the mounting for the seat cross member is damaged, the component must be replaced.

thi sd o cu m en

Note

13. Renewing seat cross member mounting

165

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht .

C op yi

Removing Note

When separating laser welded seams, ensure that the panels ly‐ ing behind are not damaged.

– Cut out seat cross member mounting.

– Release original joint.

– Remove remaining material.

166

Rep. Gr.51 - Body - centre

thi sd o cu m en

13.1

rrectness of i t to the co nf o r m spec atio h re n in wit

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

13.2

Installing

13.2.1

Preparing new part

Replacement part ♦ Seat cross member mounting – Drill 7 mm ∅ holes for SG plug weld seam.

13.2.2

Welding in

– Fit new part and secure.

– Check fit with add on parts.

– Weld in seat cross member mounting plate, SG plug weld seam.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

r te o iva r rp fo g n

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es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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– Install seat middle cross member ⇒ “14.2 Installing”, page 169 .

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AG.

13. Renewing seat cross member mounting

167

Prote cted by c o py rig ht .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 87 55 50

14

Renewing seat cross member (middle)

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; AG. Volkswagen AG d agen oes Safety instructions ksw not l o V gu y b ara d • Seat outer cross member mounting already removedrise nte o eo h ⇒ “12 Renewing seat cross member mounting”, page 162 ut r es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

ht rig py Co t.

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Rep. Gr.51 - Body - centre

thi sd o cu m en

168

ac ility ab y li an pt ce

a ss

Jetta 2005 ➤ Body Repairs - Edition 04.2009

14.1

Removing Note

When separating laser welded seams, ensure that the panels ly‐ ing behind are not damaged.

– Release original joint.

– Remove remaining material.

14.2

Installing

14.2.1

Preparing new part

Replacement part ♦ Seat cross member – Drill 7 mm ∅ holes for SG plug weld seam.

14.2.2

Welding in

– Fit new part and secure. un le

ility ab y li an pt ce

– Check fitting to adjacent components.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

pe rm itte d

– Weld in seat cross member, SG plug weld seam.

ht rig py Co t.

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AG.

14. Renewing seat cross member

do c um en

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

– Install seat outer cross member mounting ⇒ “12.2 Installing”, page 164 .

169

Prote cted by c o py rig ht .

C op yi

Jetta 2005 ➤ Body Repairs - Edition 04.2009

53 –

Body - rearAG. Volkswagen

1

Renewing cross panel

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WARNING

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Rep. Gr.53 - Body - rear

ht rig py Co t.

170

do c um en

r te o iva r rp fo g n

⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Observe safety notes!

Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

r fo ng

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Removing

ht rig py Co t.

1.1

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C op yi

– Release original joint.

1. Renewing cross panel

171

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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Installing AG.

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Preparing new part

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1.2.1

ht rig py Co t.

1.2

Replacement part Note

The replacement part is delivered without recesses for the tail light and without welding bolts. Making the recesses for the tail light and installing the welding bolts is described in ⇒ “1.2.3 Cutting out recesses for the tail light”, page 176 and ⇒ “1.2.4 Installing welding bolts”, page 178 . ♦ Cross panel ♦ Welding bolt -N 910 176 01- (qty. 8) ♦ 2K body adhesive -D 180 KD3 A2-

172

Rep. Gr.53 - Body - rear

do c um en

– Remove remaining material.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

r te o iva r rp fo g n

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es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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AG.

Prote cted by c o py rig ht .

C op yi

– Drill holes into side panel for SG plug weld seam, ∅ 7 mm.

1. Renewing cross panel

173

Jetta 2005 ➤ Body Repairs - Edition 04.2009

do c um en

ht rig py Co t.

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Prote cted by c o p yri gh t.

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Note

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

New part must be welded-in within 20 minutes or adhesion properties of adhesive will be impaired.

– Apply 2-K body adhesive -D 180 KD3 A2- in the area of the factory bonding.

1.2.2

Welding in

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

– Check fit with add on parts.

– Check rear cover closing function.

174

Rep. Gr.53 - Body - rear

Jetta 2005 ➤ Body Repairs - Edition 04.2009

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his do c um en

Note

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

When welding tail light mounting with upper side panel use a “heat shield” to prevent damage to side panel paintwork. ht rig py Co t.

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– Weld in cross panel, RP spot weld seam and SG plug weld seam.

1. Renewing cross panel

175

Prote cted by

Jetta 2005 ➤ Body Repairs - Edition 04.2009

1.2.3

Cutting out recesses for the tail light

rrectness of i t to the co nform spec at i h re o n wit in t his

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Note

– The dimensions for marking the recesses can be found in the table ⇒ page 177 .

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– Mark the recesses for the tail light and the guide.

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Note ♦ Perform parting cut with pneumatic sabre saw -V.A.G 1523- or compact angle grinder -VAS 5167- . ♦ The front side of the recesses must be parallel to the road.

– Cut out the recesses.

176

Rep. Gr.53 - Body - rear

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mm

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26.6 15.0 105.0 20.0 30.0 9.3 9.5 9.6

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Dimension

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Dimensions for the recesses for the tail

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– Check fitting to tail light and guide.

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To adjust the gaps for the tail light correctly, place washers be‐ tween the tail light and the body if necessary.

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Note

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1. Renewing cross panel

177

AG.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

1.2.4

Installing welding bolts

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Dimension a = 140 mm Dimension b = 9 mm

178

Rep. Gr.53 - Body - rear

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– Align the securing strip in the recess of the rear lid and secure it.

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– Adapt the securing strip -1- to the cross panel.

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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♦ The left side of the vehicle is shown. The figure and the work apply analogously for the right side of the

vehicle.

♦ Before adapting the guide -1-, cut out the recesses in the mounting plate

⇒ “1.2.3 Cutting out recesses for the tail light”, page 176 .

– Adapt the guide -1- to the mounting plate and secure it.

– Check fit with add on parts.

1. Renewing cross panel

179

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Note

Only the left guide is depicted -2-. The depiction and work steps also apply to the right guide.

– Mark the positions where the welding bolts for the securing strip -1- and the guide -2- are to be welded on.

180

Rep. Gr.53 - Body - rear

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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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 -1- and the securing strip -2- onto the marked positions, butt weld.

Note

If it is not possible to weld on the welding bolts, holes can be drilled and pop rivets with seals -N 907 161 01- can be riveted in alter‐ natively. In that case, speed nuts -N 907 088 01- should be used to fasten the guide and the securing strip instead of hexagonal combi bolts -N 910 189 01-

1. Renewing cross panel

181

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 10 55 00

2

Renewing mounting plate

WARNING

Observe safety notes!

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Rep. Gr.53 - Body - rear

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182

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⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

Jetta 2005 ➤ Body Repairs - Edition 04.2009

2.1

Removing

– Release original joint.

– Remove remaining material.

Installing

2.2.1

Preparing new part

Replacement part Note

The replacement part is delivered without recesses for the tail light and without welding bolts. Making the recesses for the tail light and installing the welding bolts is described in ⇒ “1.2.3 Cutting out recesses for the tail light”, page 176 and ⇒ “1.2.4 Installing welding bolts”, page 178 . c o p yri gh t .

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♦ Welding bolt -N 910 176 01- (qty. 2)

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♦ Tail light mounting

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2.2

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2. Renewing mounting plate

183

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Drill holes, as shown, into side panel for SG plug weld seam, ∅ 7 mm.

Welding in es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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– Fit new part and secure.

– Check fit with add on parts.

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Rep. Gr.53 - Body - rear

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184

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2.2.2

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Jetta 2005 ➤ - Edition 04.2009

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Note

When welding tail light mounting with upper side panel use a “heat shield” to prevent damage to side panel paintwork.

– Weld in tail light mounting , RP spot weld seam.

– Weld upper tail light mounting to side panel, SG plug weld seam.

– Cut out the recesses for the tail light and the guide ⇒ “1.2.3 Cutting out recesses for the tail light”, page 176 .

– Weld on the welding bolts for the guide ⇒ “1.2.4 Installing welding bolts”, page 178 .

2. Renewing mounting plate

185

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 24 55 50

3

Renewing luggage compartment floor

WARNING AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r Welding, parting using spark generating machines/tools or tin‐ o eo h t u ra ning in foam treated areas creates gases which a are hazardous c s to health and environment. Therefore, refrains from using these

Observe safety notes!

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processes.

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Cross panel already removed ⇒ “1 Renewing cross panel”, page 170

1 - Moulded foam element

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Rep. Gr.53 - Body - rear

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c o p yri gh t.

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186

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Note

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⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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– Separate original joint from above to the longitudinal mem‐ bers, the wheel housings and the exhaust pipe bracket.

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3.1

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3. Renewing luggage compartment floor

187

AG.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

ht rig py Co t.

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Rep. Gr.53 - Body - rear

thi sd o cu m en

188

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– Separate original joint from and to front floor panel.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Remove remaining material.

3.2

Installing

3.2.1

Preparing new part

Replacement part ♦ Rear floor panel ♦ Cross member for floor pan ♦ Moulded foam element

3. Renewing luggage compartment floor

189

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Moulded foam elements

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

Welding in

– Fit new part and secure.

– Check fitting to adjacent components.

190

Rep. Gr.53 - Body - rear

AG.

3.2.3

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Follow repair instructions.

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3.2.2

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– Drill holes for SG plug weld seam, ∅ 7 mm (distance approx.

20 mm).

Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Moulded foam elements

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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Weld in new part from above, SG plug weld seam and RP spot weld seam.

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–

3. Renewing luggage compartment floor

191

Jetta 2005 ➤ Body Repairs - Edition 04.2009

rrectness of i t to the co nf o r m spec atio h re n in wit

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

– Weld in new part from below, SG plug weld seam.

– Install cross panel ⇒ “1.2 Installing”, page 172 .

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Rep. Gr.53 - Body - rear

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192

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 47 55 50

4

Renewing longitudinal member - par‐ tial renewal

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Cross panel already removed ⇒ “1 Renewing cross panel”, page 170

•

AG Luggage compartment floor already removed agen ksw l o V page 186 ⇒ “3 Renewing luggage compartment floor”, by

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1 - Exhaust pipe bracket

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4. Renewing longitudinal member - partial renewal

193

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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Dimension -a- = 140 mm Dimension -b- = 50 mm – Remove remaining material.

194

Rep. Gr.53 - Body - rear

AG.

– Make parting cut as shown.

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– Release original joint inside and outside.

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Removing

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4.1

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Preparing new part

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4.2.1

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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4.2

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Replacement part ♦ Longitudinal member

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♦ Exhaust pipe bracket

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– Transfer parting cut to new part and cut it.

4.2.2

Welding in

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

– Check fitting to adjacent components.

4. Renewing longitudinal member - partial renewal

195

r fo ng

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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C op yi

– Weld parting cut all around, SG continuous weld seam.

– Install luggage compartment floor ⇒ “3.2 Installing”, page 189 .

– Install cross panel ⇒ “1.2 Installing”, page 172 .

196

Rep. Gr.53 - Body - rear

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

– Weld in new part, RP spot weld seam.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 48 55 50

5

Renewing rear longitudinal member end piece

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Cross panel already removed ⇒ “1 Renewing cross panel”, page 170

•

Luggage compartment floor already removed agen Apage ⇒ “3 Renewing luggage compartment floor”, n AG. Volksw G do 186 e wage

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5. Renewing rear longitudinal member end piece

197

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

– Separate original joint on longitudinal member outer side.

– Separate the SG continuous seam on the inner side of the longitudinal member.

AG.

Rep. Gr.53 - Body - rear

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198

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– Remove remaining material.

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5.1

Jetta 2005 ➤ Body Repairs - Edition 04.2009

5.2

Installing

5.2.1

Preparing new part

Replacement part ♦ Longitudinal member ♦ Exhaust pipe bracket G do es n ot g ua ran tee or ac

age ksw Vol y b ed ris o h t au ss

5.2.2

Welding in

– Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .

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– Check fitting to adjacent components.

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– Separate the longitudinal member end piece from the longitu‐ dinal member. n AG. Volkswagen A

5. Renewing rear longitudinal member end piece

199

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– Weld in new part, SG plug weld seam and SG continuous weld seam.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

– Install luggage compartment floor ⇒ “3.2 Installing”, page 189 .

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Rep. Gr.53 - Body - rear

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200

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– Install cross panel ⇒ “1.2 Installing”, page 172 .

Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 55 55 00

6

Renewing side panel - partial re‐ placement

WARNING

Observe safety notes!

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⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions

6. Renewing side panel - partial replacement

201

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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Rep. Gr.53 - Body - rear

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202

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2 - Bonded section

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1 - Moulded foam element

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. ♦ When making parting cut -2- keep overlap for replacement part in mind.

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Note

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6.1

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– Make parting cut -1- as shown.

AG.

Dimension -b- = 120 mm

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Dimension -a- = 200 mm

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♦ Make parting cut -1- only on outer panel; do not damage internal reinforcements.

– Make parting cut -2- as shown.

– Grind through outer edge on wheel arch.

– Release original joint.

6. Renewing side panel - partial replacement

203

Jetta 2005 ➤ Body Repairs - Edition 04.2009

– Separate original joint in rear window and from luggage com‐ partment -enlargement-.

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Rep. Gr.53 - Body - rear

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204

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– Grind through laser brazing seam. When doing this do not damage sealing channel underneath.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Release original joint.

– Remove remaining material.

– Remove remaining adhesive completely and grind bonded surface back to bare metal.

– Clean flange area of wheel arch so that it is free of dust and grease.

6.2

Installing

6.2.1

Preparing new part

Replacement part ♦ Side panel subpart 6. Renewing side panel - partial replacement

205

Jetta 2005 ➤ Body Repairs - Edition 04.2009 ♦ Moulded foam element ♦ 2K body adhesive -D 180 KD3 A2-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Transfer parting cut to new part and cut out.

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♦ Adhesive sealant -AKD 476 KD5 05-

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Moulded foam elements

Follow repair instructions.

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– Drill holes on side panel as shown -enlargement- (in the area of the sealing channel at the bonding area ends) for SG plug weld seam, ∅ 7 mm.

AG.

Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements

6.2.3

Welding in

– Place backing plate behind parting cuts.

206

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Note

♦ The adhesive surface must be ground back to bare metal, 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 filler neck. ♦ New part must be welded within 20 minutes, otherwise adhesive properties of adhesive will be impaired.

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– Apply 2-K body adhesive -D 180 KD3 A2- to side panel contact surface -shaded area- (1 bead, ∅ 3.5 mm).

– Apply 2-K body adhesive -D 180 KD3 A2- to wheel arch bond‐ ing area (2 beads, ∅ 3.5 mm). ht rig py Co t.

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– Adapt new part with vehicle standing on alignment bracket set or on its wheels and secure. agen lksw Vo by

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– Check fit with add on parts.

6. Renewing side panel - partial replacement

207

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– Weld in side panel, RP spot weld seam.

– Weld parting cuts, SG stepped weld seam.

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Rep. Gr.53 - Body - rear

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Weld original joint in rear window aperture, RP spot weld seam and SG plug weld seam.

– Weld side panel to sealing channel, SG plug weld seam.

– Weld in end piece, -enlargement-, RP spot weld seam.

– Bead over wheel arch flange.

– Wipe away excess adhesive and seal wheel arch.

Note

After performing repairs, reinstate laser brazing seam by using adhesive sealant -AKD 476 KD5 05- .

6. Renewing side panel - partial replacement

209

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7

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

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Rep. Gr.53 - Body - rear

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210

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

7.1

Removing

1 - Cutting point Note –

Make parting cut as shown.

–

Release original joint.

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– Remove remaining material.

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7. Renewing C-pillar reinforcement

211

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

7.2

Installing

7.2.1

Preparing new part

Replacement part ♦ C-pillar reinforcement – Transfer parting cut to the new part and cut (when doing this take 10 mm additional material for overlap into consideration -shaded area-).

– Step -shaded area- on new part.

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7.2.2

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Welding in

– Fit new part and secure.

– Weld parting cut, SG continuous weld seam (staggered).

– Weld original joint, RP spot weld seam.

– Install side panel ⇒ “6.2 Installing”, page 205 .

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Rep. Gr.53 - Body - rear

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8

Renewing outer wheel housing liner

WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions AG. Volkswagen A G do es

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au removed Side member already ss ⇒ “9 Renewing side member”, page 145

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8. Renewing outer wheel housing liner

213

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Rep. Gr.53 - Body - rear

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214

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

Removing

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– Separate original joint between inner wheel housing liner -1and outer wheel housing liner -2- in luggage compartment and passenger compartment.

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8. Renewing outer wheel housing liner

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8.1

215

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Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. c o p yri gh t .

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– Separate original joint between inner side panel and C-pillar reinforcement of wheel housing from below. agen lksw Vo by

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– Separate area to inner side member -1-.

AG.

– Remove remaining material.

– Remove remaining adhesive completely and grind bonded surface back to bare metal.

216

Rep. Gr.53 - Body - rear

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

Jetta 2005 ➤ Body Repairs - Edition 04.2009

8.2

Installing

8.2.1

Welding in

Replacement part ♦ Outer wheel housing liner ♦ 2K body adhesive -D 180 KD3 A2Note

New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.

– Apply 2-K body adhesive -D 180 KD3 A2- to inner wheel hous‐ ing liner contact surface.

– Adapt new part to fit and secure in position when vehicle is standing on its wheels or positioned on a alignment bracket .

– Check fit with side panel.

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8. Renewing outer wheel housing liner

217

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Rep. Gr.53 - Body - rear

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218

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– Weld outer wheel housing -2- to inner wheel housing -1- in luggage compartment and passenger compartment, RP spot weld seam.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

– Weld outer wheel housing liner -2- to side member reinforce‐ ment -4-, inner side panel -3- and C-pillar reinforcement -1-, RP spot weld seam.

– Install side panel ⇒ “6.2 Installing”, page 205 .

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– Install side member ⇒ “9.2 Installing”, page 148 ***

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Jetta 2005 ➤ Body Repairs - Edition 04.2009

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8. Renewing outer wheel housing liner

219

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Renewing spare wheel well - partial renewal

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WARNING

Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions •

Cross panel already removed ⇒ “1 Renewing cross panel”, page 170

9.1

Removing

Note

Make parting cut -1- as shown and cut -shaded area-.

Rep. Gr.53 - Body - rear

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220

AG.

–

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Separate original joint to floor cross member and exhaust pipe bracket.

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1 - Parting cut (partial renewal)

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Remove remaining

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9.2

Installing Preparing new part

Replacement part

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♦ Rear floor panel

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9.2.1

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– Place floor panel body side.

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9. Renewing spare wheel well - partial renewal

221

AG.

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Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Cutting point

Drill holes for SG plug weld seam, ∅ 7 mm (hole distance approx.

20 mm).

– Check fitting to adjacent components.

222

Rep. Gr.53 - Body - rear

AG.

– Fit new part and secure.

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Welding in

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9.2.2

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–

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Transfer parting cut -1to the new part and cut -shaded area- (when doing this take 10 mm additional material for overlap into considera‐ tion).

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–

Jetta 2005 ➤ Body Repairs - Edition 04.2009

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– Install cross panel ⇒ “1.2 Installing”, page 172 .

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– Weld in spare wheel recess, SG plug weld seam.

9. Renewing spare wheel well - partial renewal

223