Page 1 Service Workshop Manual Jetta 2011 ➤ Jetta Hybrid 2013 ➤ General body repairs, exterior Edition 08.2012 Service Department. Technical Information...
Page 2 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 © 2012 Volkswagen AG, Wolfsburg D3E802DF89D...
Page 3: Table Of Contents
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Contents 50 - Body - front ............
Page 4 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing rear lid ..........
Page 5 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - door hinges ..........122 Removing and installing door .
Page 6 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing rear bumper cover ........187 Assembly overview - guides for rear bumper cover .
Page 7 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing exterior mirror (manual operation) ......252 Removing and installing exterior mirror (electrical operation) .
Page 8: Jetta 2011 ➤ , Jetta Hybrid
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Contents...
Page 9: Body - Front
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 50 – Body - front Lock carrier (VRL004906; Edition 08.2012) Tools Special tools and workshop equipment required ♦ Guide pins -T 10093- ♦ Torque wrench -V.A.G 1331- ♦...
Page 10: Lock Carrier - Add-On Parts
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Lock carrier - add-on parts 1.2.1 Assembly overview 1 - Lock carrier with add-on parts ❑ Removing and installing ⇒ page 6 ❑ Service position ⇒...
Page 11: Service Position
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 15 - Support for lock carrier 16 - Retaining bracket ❑ Right. Service position 1.3.1 Moving to service position Carry out following work: – Undo bolt -3- on left and right at rear of headlight.
Page 12 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove front bumper cover ⇒ page 175 – Detach cable from cable coupling ⇒ page 45 – On vehicles with charge air cooler, remove pressure hoses ⇒...
Page 13 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.3.2 Moving from service position Carry out following work: – Push lock carrier together with add-on parts -1- on the guide pins -T10093- and onto the longitudinal member.
Page 14: Removing And Installing Lock Carrier With Add-On Parts
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing lock carrier with add-on parts 1.4.1 Removing Note The lock carrier is a safety-relevant component. It must not be repaired for this reason.
Page 15 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 must only be carried out by suitable workshops with expert mechanics; Removing and installing condenser . – Support bonnet and remove support rod from bonnet.
Page 16: Removing And Installing Pressure Hoses
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: – Fit lock carrier -1- on longitudinal members -2-. – Screw in guide pins -T10093- on left and right sides. – Moving from service position ⇒...
Page 17 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.5.2 Pressure hose with and ribbed union and hose clamp Removing pressure hose Carry out following work: – Loosen screw of hose clamp -A-. – Pull pressure hose together with hose clamp -A- off the ribbed union.
Page 18: Wing
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Wing Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. gr.50 - Body - front...
Page 19: Assembly Overview - Front Wing
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - front wing Note Only the left side is shown. The right side is similar. 1 - Wing ❑ Removing and installing ⇒ page 11 2 - Bolt ❑...
Page 20 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.3.1 Removing Carry out following work: – Remove wheel housing liners ⇒ page 236 – Pull out foam between wing and longitudinal member ⇒ Item 5 (page 11) –...
Page 21 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.3.2 Installing Note Install wing -1- without subjecting it to tensile stress. Carry out following work: Installation of the wing -1- is carried out in reverse order of re‐...
Page 22: Insulation And Foam Elements For Wing And Wing End Plate
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Insulation and foam elements for wing and wing end plate Note Only the left side is shown. The right side is similar. ♦ Different forms of insulation and foam parts may have been installed.
Page 23: Wing End Plate
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Wing end plate Note Only the left side is shown. The right side is similar. 1 - Wing end plate ❑ Placed in front of wing web plate ❑...
Page 24 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Undo bolts for fastening front wing to wing bracket -2- ⇒ page 11 – Undo bolts -1- and remove wing bracket -2-. 2.6.2 Installing Carry out following work: –...
Page 25: Plenum Chamber Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Plenum chamber cover Assembly overview - plenum chamber cover 1 - Plenum chamber, right ❑ Removing and installing ⇒ page 17 2 - Plenum chamber cover, left ❑...
Page 26 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.2.1 Removing Carry out following work: – Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ screen wiper system; Removing and installing windscreen wiper system .
Page 27 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove left plenum chamber cover -2- from vehicle towards front (in direction of travel), taking care not to damage horn between windscreen and wing.
Page 28 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note An insert is installed in windscreen seal of new windscreens. Remove this insert before installing plenum ♦ chamber cover. Push the plenum chamber cover into the windscreen seal by hand using only slight force. Never force it in ♦...
Page 29: Noise Insulation
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Noise insulation Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- 4. Noise insulation...
Page 30: Assembly Overview - Noise Insulation For Combustion Engines
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - noise insulation for combustion engines Note The removal and installation procedures may have to be modified slightly depending on engine fitted. 1 - Noise insulation ❑...
Page 31: Assembly Overview - Noise Insulation For Diesel Engines
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - noise insulation for diesel engines Note The removal and installation procedures may have to be modified slightly depending on engine fitted. 1 - Noise insulation ❑...
Page 32: Underbody Cladding
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Underbody cladding Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. gr.50 - Body - front...
Page 33: Assembly Overview - Underbody Panel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - underbody panel Note The right side is shown. The left side is similar. 1 - Underbody cladding ❑ Removing: – Unscrew hexagon nuts -2-.
Page 34: Rear Right Door Underbody Cladding
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Rear right door underbody cladding Note Slight differences may be encountered on the rear right underbody trim depending on the vehicle model. 1 - Rear right door underbody cladding ❑...
Page 35: Cross Panel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Cross panel Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Cartridge heater - V.A.G 1939- ♦ Cartridge gun -V.A.G 1628- Materials ♦...
Page 36: Assembly Overview - Bulkhead
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - bulkhead Note The bulkhead -1- is bolted and also bonded in place with PUR adhesive sealant -4-. 1 - Cross panel ❑ Removing: –...
Page 37: Tunnel Cross-Piece
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Tunnel cross-piece Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- 7. Tunnel cross-piece...
Page 38: Assembly Overview - Tunnel Cross-Piece
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - tunnel cross-piece Note -Arrow- points in direction of normal travel. 1 - Front tunnel cross-piece ❑ Removing: – Unscrew hexagon nuts -2- (2 on each side).
Page 39: Bonnet, Rear Lid
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 55 – Bonnet, rear lid Bonnet Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Removal lever -80 - 200- 1. Bonnet...
Page 40: Assembly Overview - Bonnet
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - bonnet 1 - Bonnet ❑ Removing and installing ⇒ page 33 ❑ Adjusting ⇒ page 51 2 - Adjustment buffer 3 - Seal in centre ❑...
Page 41: Removing And Installing Bonnet
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing bonnet 1.3.1 Removing Carry out following work: – Remove spray jets -5- ⇒ Electrical system; Rep. gr. 92 ; Win‐ dow washer system; Removing and installing spray jets for window washer system .
Page 42: Removing And Installing Bonnet Hinge
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.3.2 Installing Carry out following work: Installation of bonnet -1- is carried out accordingly in reverse or‐ der of removal. Note Install the line -6- in a curve. If line is installed twisted it will kink.
Page 43 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.4.1 Removing Carry out following work: – Removing bonnet -1- ⇒ page 33 – Removing plenum chamber cover ⇒ page 17 – Remove bolts -3-.
Page 44 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.4.2 Installing Carry out following work: Installation of the hinge -2- is carried out in the reverse order of removal. Specified torque for bolts -3-: 22 Nm.
Page 45: Removing And Installing Insulation
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing insulation 1.5.1 Removing Carry out following work: – Support bonnet -1- and remove support rod from bonnet. – Lever out retaining clips -3- from bonnet -1- using removal lever -80 - 200- .
Page 46 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.5.2 Installing Carry out following work: • When installing insulation -2-, ensure that retaining clips -3- are fitted with the wider side facing outwards. – Slide insulation -2- with fitting lugs into oblong holes of bonnet -1-.
Page 47: Assembly Overview - Seals
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - seals 1 - Bonnet ❑ Removing and installing ⇒ page 33 ❑ Adjusting ⇒ page 51 2 - Seal in centre ❑ Removing: –...
Page 48: Removing And Installing Support Rod
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing support rod 1.7.1 Removing Carry out following work: – Brace the bonnet open. – Swing support rod -1- upwards. – Pull support rod -1- out of rubber grommet -2-.
Page 49 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.7.2 Installing Carry out following work: – Check mounting bracket -3- for damage, renew if necessary. – Slide support rod -1- into rubber grommet -2- -arrow a-.
Page 50: Assembly Overview - Bonnet Lock And Release Components
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - bonnet lock and release components 1 - Striker pin ❑ Removing and installing ⇒ page 46 ❑ Adjusting ⇒ page 53 2 - Release lever ❑...
Page 51: Removing And Installing Lid Lock
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing lid lock 1.9.1 Removing Carry out following work: – Open bonnet. – Remove radiator grille ⇒ page 261 – Detach cable -2- from cable coupling ⇒...
Page 52 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove electric wire (if there is one) of contact switch for bon‐ net -F266- from lock carrier. – Unclip bracket -3- by squeezing catch on bracket together -arrows b-.
Page 53: Detaching Release Cable
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Screw in bolts -4-. Specified torque for bolts -4-: 12 Nm. – Attach connector for contact switch for bonnet -F266- if there is one.
Page 54: Removing And Installing Striker Pin
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note When installing cable -3-, ensure that grommets -4- and -5- are fitted correctly and securely. • Before closing bonnet, check function of release lever and re‐...
Page 55 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.11.2 Installing Carry out following work: Installation of the striker pin -2- is carried out in the reverse order of removal. Specified torque for bolts -3-: 10 Nm.
Page 56: Assembly Overview - Release Lever And Mounting Bracket
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.12 Assembly overview - release lever and mounting bracket 1 - Mounting bracket 2 - Cable ❑ Installing: – Insert ball of cable into holder on mounting bracket.
Page 57: Removing And Installing Release Lever
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.13 Removing and installing release lever 1.13.1 Removing Carry out following work: – Pull release lever -1- to release bonnet. – Insert a small screwdriver in gap between release lever -1- and retaining clip -2-.
Page 58 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.13.2 Installing Carry out following work: • Lower A-pillar trim -4- has been fitted. – Push retaining clip -2- into release lever -1-. – Press retaining lever -1- onto mounting bracket -3-.
Page 59: Adjusting Bonnet
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.14 Adjusting bonnet Note Vehicle must be standing on its wheels to enable bonnet to be adjusted. ♦ The adjustment buffers -2- on the left and right are not a means of adjustment. They have the function of ♦...
Page 60 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – After adjusting, carry out corrosion protection measures on bonnet hinges -5- and hexagon nuts -4-. – Turn adjusting buffer -2- to adjust -arrow-. – After bonnet has been adjusted, the striker pin -1- can be re- installed and adjusted ⇒...
Page 61 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.14.2 Adjusting striker pin Carry out following work: – Loosen bolts -3-. – Striker pin -2- can now be adjusted in oversized holes. Specified torque for bolts -3-: 10 Nm.
Page 62: Rear Lid
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Rear lid Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Setting gauge -3371- Rep. gr.55 - Bonnet, rear lid...
Page 63: Assembly Overview - Rear Lid
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - rear lid 1 - Rear lid ❑ Removing and installing ⇒ page 55 ❑ Adjusting ⇒ page 64 2 - Wiring harness 3 - Adjustment buffer ❑...
Page 64 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Thread electric cables/wire -2- together with rubber grommet out of rear lid -1-. – Loosen bolts -3- on left and right hinges (do not unbolt com‐...
Page 65: Assembly Overview - Gas Strut
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - gas strut 1 - Gas strut ❑ Removing and installing ⇒ page 57 ❑ Releasing gas ⇒ page 60 2 - Ball-head pin ❑...
Page 66 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 WARNING Proceed with care if gas strut is reused. Spring clip must not be levered completely out of ball socket, as it will otherwise be damaged.
Page 67 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 WARNING Proceed with care if gas strut is reused. Spring clip must not be levered completely out of ball socket, as it will otherwise be damaged.
Page 68: Releasing Gas From Gas Strut
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Releasing gas from gas strut – Clamp gas strut in vice in area x = 50 mm. WARNING Clamp gas strut only within area -x-; otherwise danger of ac‐...
Page 69: Removing And Installing Rear Lid Hinge
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing rear lid hinge 2.8.1 Removing Carry out following work: – Removing rear lid -1- ⇒ page 55 If the left hinge -6- is to be removed: –...
Page 70 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.8.2 Installing Carry out following work: Installation of hinge is carried out in reverse order of removal. Specified torque for bolts -4-: 9 Nm. – Adjusting rear lid ⇒...
Page 71: Removing And Installing Striker Plate
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing striker plate 2.9.1 Removing Carry out following work: – Remove cover of striker plate in lock carrier cover. – Undo bolts -2- and remove striker plate -1- from lock carrier -3-.
Page 72: Adjusting Rear Lid
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.10 Adjusting rear lid Note Vehicle must be standing on its wheels to enable rear lid to be adjusted. ♦ The rear lid lock -3- is bolted directly to the rear lid -1-. It does not have elongated holes, so it cannot be ♦...
Page 73: Removing And Installing Rear Lid Handle Release Button E234
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Specified torque for bolt -4-: 9 Nm. – After completing adjustments, perform corrosion protection measures on hinge and bolts. – Turn adjustment buffer -2- to adjust.
Page 74: Removing And Installing Lid Lock
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.11.2 Installing Carry out following work: Install in reverse order of removal. Specified torque for nuts: 6 Nm. • Before closing rear lid, check function of lid release compo‐...
Page 75: Removing And Installing Rear Lid Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note When seals are removed, the sealant will spread to the inside ♦ of the seal and the flanks will be bent out slightly. If the seal is then refitted, sealing and firm seating are no longer guaran‐...
Page 76 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.14.2 Installing Carry out following work: – Adjust rear lid seal -1- so that vulcanised point -arrow- faces the left tail light. – Press seal -1- evenly onto body flange -2-.
Page 77: Registration Plate Carrier
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.15 Registration plate carrier Note Number plate carrier is not installed in all models or in all markets. ♦ Number plate carriers of different sizes are fitted in various markets.
Page 78: Tank Flap Unit
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Tank flap unit Tools Special tools and workshop equipment required ♦ Removal wedge -3409- ♦ Socket -T10072- Rep. gr.55 - Bonnet, rear lid...
Page 79: Assembly Overview - Tank Flap Unit
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - tank flap unit 1 - Connector ❑ For tank filler flap lock‐ ing motor -V155- 2 - Tank filler flap locking motor -V155- ❑...
Page 80 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Using removal wedge -3409- -A-, release locking mechanism of bottom right tank flap unit -arrow 1-. – Release remaining locking mechanisms of tank flap unit using removal wedge -3409- in specified sequence -arrows 2 …...
Page 81: Removing And Installing Tank Filler Flap Locking Motor V155
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Insert tank flap unit -3- with hinge side leading into side panel -arrow a-. – Then push tank flap unit fully home in side panel -arrow b-, ensuring that locking lugs engage correctly in side panel.
Page 82 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 luggage compartment trim entirely ⇒ General body repairs, interior; Rep. gr. 70 ; Trims; Luggage and load compartment . – Detach connector -2- of tank filler flap locking motor -V155- -3-.
Page 83 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 • Carry out a functional test of the releasing components. 3. Tank flap unit...
Page 84: Front Doors, Door Components, Central Locking
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 57 – Front doors, door components, central locking Front door Tools Special tools and workshop equipment required ♦ Door alignment tool -3320- ♦ Universal joint for 3320 -3320/1- ♦...
Page 85: Assembly Overview - Door Hinges
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - door hinges Note The right side is shown. The left side is similar. ♦ The hinge bolts must always be renewed after they have been loosened.
Page 86: Removing And Installing Door
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 10 - Door retaining strap ❑ Removing and installing ⇒ page 88 11 - Bolt ❑ Qty. 2. ❑ Specified torque: 9 Nm 12 - Bolt ❑...
Page 87 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.3.1 Removing Carry out following work: – Release boot -2- by pressing fastener -arrow a- and pull off A- pillar. – Swing release lever -3- downwards -arrow b- and disconnect electrical connector -4- from coupling station.
Page 88 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.3.2 Installing Carry out following work: Install in reverse order of removal. Specified torque for bolt -5-: 30 Nm. Specified torque for bolts -7-: 23 Nm.
Page 89: Installing After Renewing A-Pillar
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Installing after renewing A-pillar WARNING If A-pillar is renewed, bolts on A-pillar must absolutely be tight‐ ened as described in the following. Carry out following work: •...
Page 90: Door Alignment
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Door alignment 1.5.1 Door alignment - shut lines and flushness Note Vehicle must be standing on its wheels to enable front door to be adjusted.
Page 91 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – For bolt -5-, A-pillar lower trim must be removed ⇒ General body repairs, interior; Rep. gr. 70 ; Pillar and side panel trim .
Page 92: Door Components
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Door components Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Socket -3410- ♦ Roller for door insulation foil -3356- ♦ Removal wedge -3409- ♦...
Page 93: Assembly Overview - Front Door
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - front door 1 - Door ❑ Removing and installing ⇒ page 78 ❑ Adjusting ⇒ page 82 2 - Cable ❑ From bearing bracket...
Page 94: Removing And Installing Door Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ❑ Specified torque: 9 Nm 17 - Door retaining strap ❑ Removing and installing ⇒ page 88 18 - Window slot inner seal ❑ Removing and installing ⇒...
Page 95 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: – Removing front door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Lift lower end of cover -1-.
Page 96: Removing And Installing Door Retaining Strap
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing door retaining strap Note Removal and installation are described only for the right door re‐ taining strap. The removal and installation of the left door retaining strap is similar.
Page 97: Removing And Installing Striker Pin
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.4.2 Installing Carry out following work: Install in reverse order of removal. Specified torque for bolt -2-: 30 Nm. Specified torque for bolts -3-: 9 Nm.
Page 98 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.5.1 Removing Carry out following work: – Unscrew bolt -2- and remove striker pin -1-. 2.5.2 Installing Carry out following work: – Position striker pin -1- on B-pillar -3- and tighten bolts -2-.
Page 99: Assembly Overview - Door Handle And Door Lock
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - door handle and door lock Note Only the left side is shown. The right side is similar. 1 - Door lock ❑ Removing and installing ⇒...
Page 100: Removing And Installing Lock Cylinder Cover Cap
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing lock cylinder cover cap 2.7.1 Removing Note When removing lock cylinder cover cap, the screwdriver should not be turned and the screwdriver should not be used as a lever.
Page 101: Removing And Installing Lock Cylinder
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing lock cylinder Note The removal and installation sequence is only for the left lock cyl‐ inder. The removal and installation of the right lock cylinder is similar.
Page 102 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Unscrew bolt -7- to stop so that bolt releases lock cylinder. – Pull door handle -2- off door -8- -arrow a-. – Pull lock cylinder housing -1- perpendicular -arrow b- to the door out of the bearing bracket -3-.
Page 103: Removing And Installing Cover Cap (Without Lock Cylinder)
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 • It is essential that a functional check is then performed with the door open. Removing and installing cover cap (without lock cylinder) 2.9.1 Tools Special tools and workshop equipment required ♦...
Page 104 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.9.2 Removing Note Forms other than the cover shown here -2- may also be installed. Carry out following work: – Remove cover -2-. – Insert assembly tool -T10389- into door behind locking hook -3- for cover cap -1-.
Page 105 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Pull door handle -2- off door in direction of -arrow a-. – Pull cover cap -1- out of bearing bracket -arrow b- at a right angle.
Page 106: Removing And Installing Door Handle
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Insert screwdriver -4- up to locking hook -3- in bearing bracket. – Press cover cap -1- onto door. – Push screwdriver -arrow- so far into hole until hook locks in place.
Page 107 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.10.1 Removing Carry out following work: – Remove lock cylinder ⇒ page 93 or cover cap ⇒ page 95 – Pull door handle -1- towards rear slightly -arrow a- until it comes out of mounting of bearing bracket.
Page 108: Removing And Installing Door Lock
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.10.2 Installing Carry out following work: – Connect connector (if there is one) to door handle -1-. – Seat door handle -1- in bearing bracket, whereby handle must be at right angles to door -arrow a-.
Page 109 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.11.1 Removing Carry out following work: – Remove cover ⇒ page 86 – Unclip cover -3-. – Disconnect connector -4-. – Remove lock cylinder if it is built into door ⇒...
Page 110 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Swivel cable -arrow b- so far until cable can be threaded out of eye in door lock -1- -arrow c-. Detach cable from interior door handle –...
Page 111: Removing And Installing Bearing Bracket
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Install in reverse order of removal. Specified torque for bolts -2-: 18 Nm. • It is essential that a functional test is then carried out because the door lock is not released if the cables are not correctly adjusted and locked and the door cannot then be opened.
Page 112 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.12.1 Removing Carry out following work: – Remove cover ⇒ page 86 – Remove lock cylinder ⇒ page 93 or cover cap ⇒ page 95 –...
Page 113: Removing And Installing Window Slot Inner Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.12.2 Installing Carry out following work: Install in reverse order of removal. Specified torque for bolt -4-: 1 Nm. 2.13 Removing and installing window slot in‐...
Page 114 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.13.1 Removing Carry out following work: – Removing front door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Pull seal -1- uniformly -arrows- off door flange -2-.
Page 115 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.13.2 Installing Carry out following work: – Push seal -1- evenly onto door flange -2- by hand, starting from B-pillar. – Install front door trim ⇒ General body repairs, interior; Rep.
Page 116: Removing And Installing Window Slot Outer Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.14 Removing and installing window slot outer seal 2.14.1 Removing Note The core of the seal is a metal insert. ♦ If this is bent, the seal can no longer be straightened out. It will ♦...
Page 117: Removing And Installing Door Inner Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: – Remove exterior mirror, manual operation ⇒ page 252 , elec‐ trical operation ⇒ page 256 – Pull seal -1- uniformly -arrows- off door flange -2-.
Page 118 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note When removing the seal, the sealant is distributed across the ♦ inside of the seal. The sides are bent upwards slightly when this is being done. If the seal is then refitted, sealing and firm seating are no longer guaranteed.
Page 119 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove sill panel strip ⇒ General body repairs, interior; Rep. gr. 68 ; Sill panel strips . – Pull door inner seal -1- off body flange.
Page 120: Removing And Installing Door Outer Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.16 Removing and installing door outer seal Note Removal and installation are described only for the right door ♦ outer seal. Removal and installation of the left door outer seal are similar.
Page 121 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.16.2 Installing Carry out following work: • The clips -2- are not damaged, otherwise renew. – Press seal -1- with clips -2- onto door -3- beginning at A-pillar.
Page 122: Assembly Overview - Insulation
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.17 Assembly overview - insulation WARNING Before installing door trim, check that the holes in the door panel are sealed with respective stickers ⇒ page 114 1 - Insulation ❑...
Page 123: Central Locking
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Central locking Fitting location overview - central locking components 1 - Coupling station ❑ Fitting location: left A- pillar ❑ To separate connec‐ tions, release bellows at pillar.
Page 124: Adapting Keys With Remote Control
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 10 - Rear left door lock ❑ Door lock is secured to inner part of door. ❑ Electric central locking is integrated into door lock.
Page 125: Assembly Overview - Battery For Folding Key With Remote Control
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ 09 - Onboard supply control unit ♦ 09 - Functions ♦ Adapting key with remote control Assembly overview - battery for folding key with remote control...
Page 126: Removing And Installing Battery For Folding Key With Remote Control
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing battery for fold‐ ing key with remote control 3.4.1 Removing Carry out following work: – Insert screwdriver in slot between transmitter unit -1- and key -2-.
Page 127: Assembly Overview - Battery For Folding Key With Cover Cap
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: Ensure correct polarity and mounting position when installing bat‐ tery. – Lay battery -1- with positive terminal downwards in sender unit -2- (positive terminal is marked on housing).
Page 128: Removing And Installing Battery For Folding Key With Cover Cap
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing battery for fold‐ ing key with cover cap 3.6.1 Removing Carry out following work: – Fold out profile section of key. – Using a screwdriver, unclip cover cap -1- on back of key -2- in -direction of arrow-.
Page 129: Rear Doors, Door Components
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 58 – Rear doors, door components Rear door Tools Special tools and workshop equipment required ♦ Door alignment tool -3320- ♦ Universal joint for 3320 -3320/1- ♦...
Page 130: Assembly Overview - Door Hinges
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - door hinges Note The right side is shown. The left side is similar. ♦ The hinge bolts must always be renewed after they have been loosened.
Page 131: Removing And Installing Door
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 10 - Door retaining strap ❑ Removing and installing ⇒ page 132 11 - Bolt ❑ Qty. 2. ❑ Specified torque: 9 Nm Removing and installing door Note The removal and installation sequence is only for the right door.
Page 132 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Swing release lever -3- downwards -arrow b- and disconnect electrical connector -4- from coupling station. – Remove caps -8- from bolts -7-. – Loosen bolts -7- at hinges -arrow d-.
Page 133: Installing After Renewing B-Pillar
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Installing after renewing B-pillar WARNING If B-pillar is renewed, bolts on B-pillar must absolutely be tight‐ ened as described in the following. Carry out following work: •...
Page 134: Door Alignment
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Door alignment 1.5.1 Door alignment - shut lines and flushness Note Vehicle must be standing on its wheels to enable rear door to be adjusted.
Page 135 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – For bolts -5-, B-pillar lower trim must be removed ⇒ General body repairs, interior; Rep. gr. 70 ; Pillar and side panel trims .
Page 136: Door Components
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Door components Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Socket -3410- ♦ Roller for door insulation foil -3356- ♦ Removal wedge -3409- ♦...
Page 137: Assembly Overview - Rear Door
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - rear door 1 - Door ❑ Removing and installing ⇒ page 123 ❑ Adjusting ⇒ page 126 2 - Window slot outer seal ❑...
Page 138: Removing And Installing Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 19 - Window slot inner seal ❑ Removing and installing ⇒ page 145 20 - Door window ❑ Removing and installing ⇒ page 221 Removing and installing cover Note The removal and installation sequence is only for the right cover.
Page 139 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove cover -1- from door -4-. Note If required for subsequent work, pull cable -2- with grommet -3- out of cover -1-. 2.3.2 Installing Carry out following work: –...
Page 140: Removing And Installing Door Retaining Strap
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing door retaining strap Note Removal and installation are described only for the right door re‐ taining strap. The removal and installation of the left door retaining strap is similar.
Page 141: Removing And Installing Striker Pin
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.4.2 Installing Carry out following work: Install in reverse order of removal. Specified torque for bolt -2-: 30 Nm. Specified torque for bolts -3-: 9 Nm.
Page 142 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.5.1 Removing Carry out following work: – Unscrew bolt -2- and remove striker pin -1-. 2.5.2 Installing Carry out following work: – Place striker pin -1- on C-pillar and tighten bolts -2-.
Page 143: Assembly Overview - Door Handle And Door Lock
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - door handle and door lock Note The right side is shown. The left side is similar. 1 - Bolt ❑ Qty. 2.
Page 144 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Assembly tool -T10389- 2.7.2 Removing Carry out following work: – Remove door outer seal -5- in area of hole for locking hook ⇒ page 152 –...
Page 145 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Pull assembly tool -T10389- backwards -arrow- until locking hook releases. – Pull door handle -2- off door in direction of -arrow a-. – Pull cover cap -1- out of bearing bracket -arrow b- at a right angle.
Page 146: Removing And Installing Door Handle
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Insert screwdriver -4- up to locking hook -3- in bearing bracket. – Press cover cap -1- onto door. – Push screwdriver -arrow- so far into hole until hook locks in place.
Page 147 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.8.1 Removing Carry out following work: – Remove cover cap ⇒ page 135 – Pull door handle -1- towards rear slightly -arrow a- until it comes out of mounting of bearing bracket.
Page 148: Removing And Installing Door Lock
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.8.2 Installing Carry out following work: – Seat door handle -1- in bearing bracket, whereby handle must be at right angles to door -arrow a-.
Page 149 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.9.1 Removing Carry out following work: – Remove cover ⇒ page 130 – Unplug connector -1- from door lock. – Remove bolts -4-. – Remove door lock -1- from door -2-.
Page 150 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Detach cable from interior door handle – Turn cable -6- 90° and take it out of holding device. – Swivel cable -arrow d- so far until cable can be threaded out of eye in door lock -1- -arrow e-.
Page 151: Removing And Installing Bearing Bracket
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Install in reverse order of removal. Specified torque for bolts -4-: 18 Nm. • It is essential that a functional test is then carried out because the door lock is not released if the cables are not correctly adjusted and locked and the door cannot then be opened.
Page 152 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.10.1 Removing Carry out following work: – Remove cover ⇒ page 130 – Remove cover cap ⇒ page 135 – Remove door handle ⇒ page 138 –...
Page 153: Removing And Installing Window Slot Inner Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.10.2 Installing Carry out following work: Install in reverse order of removal. Specified torque for bolt -4-: 1 Nm. 2.11 Removing and installing window slot in‐...
Page 154 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.11.1 Removing Carry out following work: – Remove rear door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Pull seal -1- uniformly -arrows- off flange -2-.
Page 155 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.11.2 Installing Carry out following work: – Push seal -1- evenly onto door flange -2- by hand, starting from B-pillar. – Install rear door trim ⇒ General body repairs, interior; Rep. gr.
Page 156: Removing And Installing Window Slot Outer Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.12 Removing and installing window slot outer seal 2.12.1 Removing Note The core of the seal is a metal insert. If this is bent, the seal ♦...
Page 157: Removing And Installing Door Inner Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.12.2 Installing Carry out following work: – Align seal -1- with B-pillar and press evenly onto door flange -2- by hand. 2.13 Removing and installing door inner seal During production, a sealant is applied to the door inner seals, which are then placed on the door flange and rolled on.
Page 158 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note When removing the seal, the sealant is distributed across the ♦ inside of the seal. The sides are bent upwards slightly when this is being done. If the seal is then refitted, sealing and firm seating are no longer guaranteed.
Page 159 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove sill panel strip ⇒ General body repairs, interior; Rep. gr. 68 ; Sill panel strips . – Pull door inner seal -1- off body flange -2-.
Page 160: Removing And Installing Door Outer Seal
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.14 Removing and installing door outer seal Note Removal and installation are described only for the right door ♦ outer seal. Removal and installation of the left door outer seal are similar.
Page 161 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.14.2 Installing Carry out following work: • The clips -2- are not damaged, otherwise renew. – Press door outer seal -1- onto door -3-, starting at B-pillar.
Page 162: Assembly Overview - Insulation
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.15 Assembly overview - insulation 1 - Insulation ❑ Self-adhesive. ❑ Installing: – Cut to size if necessary. – Warm using hot air blower -V.A.G 1416- and push on to outer door panel with force.
Page 163: Sunroof
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 60 – Sunroof Sunroof with glass panel Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Function All actions of the sliding/tilting roof can be performed with ignition switched on.
Page 164: Assembly Overview
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview 1 - Glass panel for sliding/tilting sunroof (single pane safety glass) ❑ Removing and installing ⇒ page 157 ❑ Height adjustment ⇒ page 158 ❑...
Page 165: Removing And Installing Sliding/Tilting Sunroof Glass Panel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing sliding/tilting sunroof glass panel 1.4.1 Removing Carry out following work: – Push sliding headliner to rear. – Raise sliding/tilting sunroof – Unclip bellows along lower strip.
Page 166: Height-Adjustment Of Glass Panel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Screw in bolts -1- and -3- but only tighten slightly; do not tight‐ en fully until height of glass panel has been adjusted. – Carry out height-adjustment of glass panel ⇒...
Page 167: Checking Parallel Running Of Glass Panel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Height-adjustment of glass panel at rear (-arrow- points in direc‐ tion of travel). -b- = 0…1 mm higher than roof line – Tighten rear bolt for glass panel.
Page 168: Adjusting Parallel Running Of Glass Panel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Adjusting parallel running of glass panel Note Parallel running can only be adjusted if sliding/tilting sunroof drive and glass panel have been removed (in "0" position).
Page 169: Removing And Installing Sliding Headlining
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Unclip wind deflector -1- from carrier unit -2- -arrows-. Caution The wind deflector and the pivot point are preloaded by the wind deflector spring. This preload must not be released by loosening the pivot point screws as otherwise the thread in the assembly unit will become damaged.
Page 170: Removing And Installing Sliding/Tilting Sunroof Drive
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Unscrew and remove front screws -arrow- on left and right. – Push spring slide forwards over stop -1- and take out. – Push sliding headliner forwards and raise slightly above the roof cut-out.
Page 171: Setting Drive For Sliding/Tilting Sunroof To Zero Position
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Undo bolts -arrows- and pull off drive for sliding/tilting roof -1-. – Detach connector -2- from drive for sliding/tilting roof. 1.11.2 Installing Carry out following work: •...
Page 172: Removing Pre-Selector Control For Sliding/Tilting Sunroof
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – The glass panel is opened and moves towards the rear as far as the end stop; it is then moved forwards until it finally closes.
Page 173: Removing And Installing Carrier Unit
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.15 Removing and installing carrier unit 1.15.1 Removing Carry out following work: – Lower moulded headliner (do not remove from vehicle) ⇒ General body repairs, interior; Rep. gr. 70 ; Roof trims .
Page 174 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.15.2 Installing Carry out following work: – Fit carrier unit -1- into roof aperture with the help of a second mechanic. – During installation, use two cylindrical pins (inverted drill bits) to align carrier unit -1- front right 12 mm -4- and rear left 10 mm -2- in roof.
Page 175: Cleaning Water Drain Hoses
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Fit water drainage hoses onto nozzles -arrows- of carrier unit -1-. – Install moulded headliner ⇒ General body repairs, interior; Rep. gr. 70 ; Roof trim .
Page 176 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.16.2 Rear water drain hoses The rear water drainage hoses run through the C-pillars and end in the rear wheel housings. Cleaning is done from the wheel housing.
Page 177: Bumpers
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 63 – Bumpers Front bumper cover Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1332- Repairing front bumper cover...
Page 178: Jetta 2011 ➤ , Jetta Hybrid
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Installation tool for PDC bracket -VAS 6614- ♦ Cartridge gun -VAS 5155- 1.3.2 Materials ♦ 2-component plastic adhe‐ sive -D 180 K2 A1- ♦ Bonding agent for plastics -D 822 150 A1- ♦...
Page 179 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 The 4 markings for a bracket -1- can be found on the inside of the bumper cover. – If there are no markings, the centre point -2- must be deter‐...
Page 180 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Fix the hole puncher in position with bolt head -1-, washer -2- and thrust bearing -3- from the inside of the bumper cover -5-.
Page 181 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note Approx. 1 cm of adhesive from tip should not be applied. – Lightly sand inside of bumper cover -6- and clean thoroughly. – Apply primer to bumper cover and bracket and allow to air for 10 minutes.
Page 182: Assembly Overview - Front Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Apply adhesive as shown in illustration and tighten knurled nut -2-. – Remove all centring pins after minimum curing period, mini‐ mum curing period ⇒...
Page 183: Removing And Installing Front Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing front bumper cover Note The removal and installation procedures for front bumper cover may have to be revised slightly depending on model variations.
Page 184 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Pull out front bumper cover -1- from fasteners of guides on left and right of wing -arrows a-. – With the aid of a second mechanic, pull front bumper cover -1- parallel -arrows d- off vehicle.
Page 185: Front Bumper Cover Add-On Parts
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Press front bumper cover -1- onto guides on left and right on wing until they engage with each other. – Ensure joints are parallel and shut lines are equal ⇒ Body Re‐...
Page 186: Installing Front Number Plate Carrier
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 9 - Cover ❑ For towing eye. Installing front number plate carrier Note Number plate carrier is not installed in all models or in all markets.
Page 187: Assembly Overview - Guides For Front Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Holes do not exist – Centre the number plate carrier -3- on front bumper cover -2- in relation to VW emblem -1-. – Set drill depth stop to 12 mm and drill holes.
Page 188: Assembly Overview - Front Bumper Carrier
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - front bumper carrier 1 - Front bumper carrier 2 - Bolt ❑ Qty. 2 on each side. ❑ Specified torque: 8 Nm 3 - Foam element ❑...
Page 189: Rear Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Rear bumper cover Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1331- Repairing rear bumper cover Note If rear bumper cover is damaged, determine whether plastic can be repaired before renewing bumper.
Page 190 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Installation tool for PDC bracket -VAS 6614- ♦ Cartridge gun -VAS 5155- 2.3.2 Materials ♦ 2-component plastic adhe‐ sive -D 180 K2 A1- ♦ Bonding agent for plastics -D 822 150 A1- ♦...
Page 191 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 The 4 markings for a bracket -1- can be found on the inside of the bumper cover. – If there are no markings, the centre point -2- must be deter‐...
Page 192 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Fix the hole puncher in position with bolt head -1-, washer -2- and thrust bearing -3- from the inside of the bumper cover -5-.
Page 193 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note Approx. 1 cm of adhesive from tip should not be applied. – Lightly sand inside of bumper cover -6- and clean thoroughly. – Apply primer to bumper cover and bracket and allow to air for 10 minutes.
Page 194: Assembly Overview - Rear Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Apply adhesive as shown in illustration and tighten knurled nut -2-. – Remove all centring pins after minimum curing period, mini‐ mum curing period ⇒...
Page 195: Removing And Installing Rear Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing rear bumper cover Note The removal and installation procedures for rear bumper cover may have to be revised slightly depending on model variations.
Page 196 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – If fitted, remove securing bolts of underbody panel at rear right on bumper cover. Further dismantling requires the assistance of a second mechan‐ – Pull rear bumper cover -1- out of fasteners of guides on left and right of side panel -arrows b-.
Page 197: Assembly Overview - Guides For Rear Bumper Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Place rear bumper cover -1- parallel onto guide on vehicle until rear bumper cover -1- engages retaining brackets -2- on left and right -arrows a-.
Page 198: Assembly Overview - Rear Bumper Carrier
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - rear bumper carrier 1 - Rear bumper carrier 2 - Bolt ❑ Qty. 3 on each side. ❑ Specified torque: 20 Nm 3 - Foam element ❑...
Page 199 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1 - Towing bracket ❑ With detachable ball head ❑ Remove rear bumper cover ⇒ page 187 2 - Bolt ❑ Sealing plugs ❑ Qty. 1 on left ❑...
Page 200: Glazing
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 64 – Glazing Flush bonded windows Tools Note The removal of a bonded window is described using the Removal kit for flush bonded windows -V.A.G 1474 A- .
Page 201: Materials
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Electric cutter - V.A.G 1561 A- ♦ Cutting blade - V.A.G 1561/2- ♦ Cutting blade - V.A.G 1561/8- ♦ Assembly tool set -T10237- ♦ Cutting blade - V.A.G 1561/19-...
Page 202: Repairing Windscreen
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Heat according to manufacturer's instructions, using cartridge heater -V.A.G 1939- . Small cartridge, 180 ml, for sealing and/or when a 400 ml dou‐ ble cartridge alone is not sufficient.
Page 203: Assembly Overview - Windscreen
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - windscreen 1 - Windscreen ❑ Removing ⇒ page 195 ❑ Installing ⇒ page 197 2 - PUR adhesive sealant ❑ Cross section of bead: -width b- = 7.5 mm,...
Page 204 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – If featured, remove water channel ⇒ page 274 – Removing plenum chamber cover ⇒ page 17 – Slide protective backing -V.A.G 1474/8- -1- between front windscreen and dash panel.
Page 205: Installing Windscreen
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Secure other end of cord to reel device -V.A.G 1654 A- . – Apply the reel device -V.A.G 1654 A- to “position I”. – Turn reel device -V.A.G 1654 A- accordingly and cut wind‐...
Page 206: Assembly Overview - Rear Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - rear window 1 - Rear window ❑ Removing ⇒ page 198 ❑ Installing ⇒ page 200 2 - PUR adhesive sealant ❑ Cross section of bead: -width b- = 6.5 mm,...
Page 207: Removing Broken Rear Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Pull cutting cord -2- through adhesive sealing material to in‐ side using awl -V.A.G 1474/2- -1-. – Secure end of cutting cord using pull handle -V.A.G 1351/1- to prevent it from falling out.
Page 208: Installing Rear Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Cover flange -2- all round with textile-reinforced adhesive tape. – Cut through adhesive seal (with glass remains) in window cut- out using electric cutter -V.A.G 1561 A- and u-shaped blade - V.A.G 1561- .
Page 209: Preparing Old Undamaged Window For Glazing
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.11 Preparing old undamaged window for glazing 1.11.1 Cutting back adhesive bead Carry out following work: Note If an undamaged window is being re-used, cut back the resid‐...
Page 210: Preparing Body Flange For Glazing
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Then use applicator -D 009 500 25- -1- to apply glass and paint primer -2- evenly in one stroke. ♦ Drying time approx. 10 minutes 1.13...
Page 211: Installation Instructions
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.14 Installation instructions Carry out following work: – Apply adhesive sealing material in continuous bead, holding applicator at right angle to window. WARNING Window must be installed within 10 minutes, or adhesive prop‐...
Page 212 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 WARNING When cleaning freshly installed glass from the inside in the ve‐ hicle, do not press glass outwards. – First clean painted surface as well as possible using a dry cloth.
Page 213: Front Door Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Front door window Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- 2. Front door window...
Page 214: Assembly Overview - Front Door Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - front door window Note The right side is shown. The left side is similar. 1 - Retaining clip 2 - Door window ❑...
Page 215 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.3.1 Removing Carry out following work: – Removing front door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Remove cover -2- ⇒...
Page 216 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Caution Loosening clamping bolt -3- by turning it clockwise. – Loosen clamping bolt -3- by turning it clockwise (do not re‐ move) and press clamping jaws -4- apart.
Page 217 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.3.2 Installing Carry out following work: – Insert door window -1- into window channels -2- -arrow a-. – Insert door window into B-pillar window channel -arrow A- and push into clamping brackets as far as it will go -arrow B-.
Page 218 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Using both hands, push door window into B-pillar window channel as far as it would go -arrow-. – Using both hands, push door window downwards -arrow B-.
Page 219 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note The door window will seat correctly in the window channel -arrow- if this procedure is carried out correctly. • Before the cover cap -5-, the cover -2- and the door trim are installed, carry out a functional test.
Page 220: Removing And Installing Window Regulator Motor
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing window regula‐ tor motor Note The removal and installation sequence is only for the right window regulator motor. The removal and installation of the left window regulator motor is similar.
Page 221 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Caution ♦ Switch off ignition and all electrical consumers. ♦ Remove ignition key. – Disconnect connector -2-. – Remove the three screws -3-. – Remove window regulator motor together with control unit -1- from mounting brackets.
Page 222: Removing And Installing Window Regulator
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: – Position window regulator motor -1- on mounting brackets of cable drum. Move door window up and down slightly so that the splines between window regulator motor and cable drum engage more easily.
Page 223 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.5.1 Removing Carry out following work: – Remove door window ⇒ page 206 – Removing window regulator motor ⇒ page 212 – Release locking hook of cable drum -arrows b- and push into door.
Page 224 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.5.2 Installing Carry out following work: – Insert window regulator -2- together with cable drum through opening in door -arrows a-, -b- and -c-. – Insert upper threaded bolts with nuts -3- through the door skin and move in -direction of arrow d-.
Page 225: Removing And Installing Window Channel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing window chan‐ Note Removal and installation is described only for the right window ♦ channel. The removal and installation of the left window chan‐...
Page 226 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Peel sealing lip of window channel -1- off the door flange from the inside. – Pull window channel -1- -arrows a- off flange -2- uniformly all around it.
Page 227 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note To prevent wind noise, ensure window channel -1- seats evenly when installing. – Push in retaining clip -3- -arrow c-. Note ♦ Retaining clip inclination must point to inner side of vehicle (vehicle interior).
Page 228: Rear Door Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Rear door window Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. gr.64 - Glazing...
Page 229: Assembly Overview - Rear Door Windows
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - rear door windows Note The right side is shown. The left side is similar. 1 - Door window ❑ Removing and installing ⇒...
Page 230 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.3.1 Removing Carry out following work: – Remove rear door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Lower door window -6- as far as stop.
Page 231 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Raise door window -6- until spreader pin -4- and spreader plug -3- are accessible in cut-out of window regulator -2-. – Screw a 5 mm bolt (approx. 70 mm long) in the spreader pin -4- and pull bolt out of spreader plug -3-.
Page 232 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.3.2 Installing Note When installing door window, always renew spreader plug -3- and spreader pin -4-. ♦ Before inserting spreader plug -3- and spreader pin -4-, check window -1- for damage.
Page 233: Removing And Installing Window Regulator Motor
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing window regula‐ tor motor Note The removal and installation sequence is only for the right window regulator motor. The removal and installation of the left window regulator motor is similar.
Page 234 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Caution ♦ Switch off ignition and all electrical consumers. ♦ Remove ignition key. – Disconnect connector -3-. – Remove the three screws -2-. – Remove window regulator motor together with control unit -1- from mounting brackets.
Page 235: Removing And Installing Window Regulator
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: – Position window regulator motor -1- on mounting brackets of cable drum. Move door window up and down slightly so that the splines between window regulator motor and cable drum engage more easily.
Page 236 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.5.1 Removing Carry out following work: – Remove cover ⇒ page 130 – Remove door window ⇒ page 221 – Removing window regulator motor ⇒ page 225 –...
Page 237 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.5.2 Installing Carry out following work: – Insert window regulator -1- together with cable drum through opening in door and move to mounting position -arrows a- and -b-.
Page 238: Removing And Installing Window Channel
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing window chan‐ Note Removal and installation is described only for the right window channel. The removal and installation of the left window channel is similar.
Page 239 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.6.2 Installing Carry out following work: – Openings -4- beneath window channel are masked off with textile adhesive tape. Adhesive tape dimensions: height = approx. 10 mm, width = ap‐...
Page 240: Removing And Installing Fixed Door Window
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note To prevent wind noise, ensure window channel -1- seats evenly when installing. ♦ The window channel is installed at the B-pillar after installation of the door window.
Page 241 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.7.1 Removing Carry out following work: – Remove window channel ⇒ page 230 – Lever out cover caps -1-. – Remove bolts -2-. – Pull fixed door window -3- away from the door -4- only until the clips -5- disengage.
Page 242 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.7.2 Installing Carry out following work: – Push fixed door window -1- into door -2-. – Press fixed door window -1- evenly onto door -2- until the clips -3- engage.
Page 243: Exterior Equipment
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 66 – Exterior equipment Wheel housing liner Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- 1. Wheel housing liner...
Page 244: Assembly Overview - Front Wheel Housing Liner
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - front wheel housing liner Note ♦ Minor differences may be encountered in respect of wheel housing liner, depending on vehicle model. Only the left side is shown. The right side is similar.
Page 245 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.3.1 Removing Carry out following work: – Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐ ques for wheel bolts . – Remove bolts -2- (Qty. 12).
Page 246 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.3.2 Installing Carry out following work: Note Check spreader nuts -3- for damage and renew if necessary. – Insert wheel housing liner -1- into wing.
Page 247: Assembly Overview - Rear Wheel Housing Liner
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - rear wheel housing liner Note Minor differences may be encountered in respect of wheel housing liner, depending on vehicle model. ♦ Only the left side is shown. The right side is similar.
Page 248: Removing And Installing Rear Wheel Housing Liner
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing rear wheel housing liner 1.5.1 Removing Carry out following work: – Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐...
Page 249 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 1.5.2 Installing Carry out following work: Note Check spreader nuts -3- for damage and renew if necessary. WARNING ♦ Check gas-tight spreader nuts -4- for damage and renew if necessary.
Page 250 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Fit wheel ⇒ Running gear; Rep. gr. 44 ; Specified torques for wheel bolts Rep. gr.66 - Exterior equipment...
Page 251: Exterior Mirror
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Exterior mirror Tools Special tools and workshop equipment required ♦ Wedges -T10383- ♦ Torque wrench -V.A.G 1783- 2. Exterior mirror...
Page 252: Assembly Overview - Exterior Mirror (Manual Operation)
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - exterior mirror (manual operation) Note The right side is shown. The left side is similar. 1 - Mirror housing ❑ Material: ABS.
Page 253: Assembly Overview - Exterior Mirror (Electric Operation)
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - exterior mirror (electric operation) Note The right side is shown. The left side is similar. 1 - Mirror housing ❑ Material: ABS.
Page 254 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.4.1 Removing Carry out following work: WARNING When doing this repair work, always wear safety goggles and leather gloves! – Protect edge of housing -2- against paint damage with e.g.
Page 255: Removing And Installing Trim
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.4.2 Installing Carry out following work: – Press connector contacts onto mirror glass. – Push mirror glass centrally onto adjustment unit in housing. Mirror glass engages audibly.
Page 256: Removing And Installing Mirror Housing
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Disengage locking hook -4- on trim -1- -arrow a-. – Swivel trim -1- off retaining lugs -2- -arrow b-. – Remove trim -1- from mirror mounting -3-.
Page 257 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.6.1 Removing Carry out following work: – Remove mirror glass ⇒ page 245 – Remove trim ⇒ page 247 – Disengage locking hooks -2- at mirror housing -1- -arrow-.
Page 258: Removing And Installing Adjustment Unit With Motor For Exterior Mirror
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.6.2 Installing Carry out following work: – Press mirror housing -1- onto mirror mounting -3- until locking hooks -2- engage audibly. – Installing trim ⇒ page 247 –...
Page 259 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.7.1 Removing Carry out following work: – Remove mirror glass ⇒ page 245 – Undo bolts -2- (3 bolts) and remove adjustment unit together with motor -1- from mirror mounting.
Page 260: Removing And Installing Exterior Mirror (Manual Operation)
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.7.2 Installing Carry out following work: – Connect connector -3- to adjustment unit with motor -1-. – Place adjustment unit with motor -1- on mirror mounting and fix in place by tightening screws -2- (qty.
Page 261 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.8.1 Removing Carry out following work: – Removing front door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Detach connector (if there is one) for electric mirror heater.
Page 262 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Swivel lower part of exterior mirror -1- away from the door a little -arrow a- and pull it downwards out of the window channel -2- -arrow b-.
Page 263 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.8.2 Installing Carry out following work: – Check that the foam part -4- is correctly installed in the door. – Thread cables for operating the exterior mirror -3- through opening in door.
Page 264: Removing And Installing Exterior Mirror (Electrical Operation)
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Screw in and tighten bolt -2- for exterior mirror -1-. Specified torque for bolt -2-: 8 Nm. – Attach connector (if there is one) for electric mirror heater.
Page 265 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.9.1 Removing Carry out following work: – Removing front door trim ⇒ General body repairs, interior; Rep. gr. 70 ; Door trim . – Detach connector -2- for exterior mirror -1-.
Page 266 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Swivel lower part of exterior mirror -1- away from the door a little -arrow a- and pull it downwards out of the window channel -2- -arrow b-.
Page 267 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 2.9.2 Installing Carry out following work: – Check that the foam part -4- is correctly installed in the door. – Thread electric cable for exterior mirror -3- through opening in door.
Page 268 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Screw in and tighten bolt -3- for exterior mirror -1-. Specified torque for bolt -3-: 8 Nm. – Connect connector -2- for exterior mirror -1-.
Page 269: Radiator Grille
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Radiator grille Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Removing and installing radiator grille Note The description applies to all models.
Page 270 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.2.1 Removing Carry out following work: – Remove bolts -3-. – Pull radiator grille -1- out of front bumper cover -2- in direction of -arrow a-.
Page 271 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.2.2 Installing Carry out following work: – Push radiator grille -1- into front bumper cover -2-. – With slight pressure, engage radiator grille -1- -arrow b- in front bumper cover -2-.
Page 272: Removing And Installing Emblem
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing emblem 3.3.1 Removing Carry out following work: – Remove radiator grille ⇒ page 261 – Disengage all locking hooks -arrows- of the trim cover with VW emblem -1-.
Page 273 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Disengage upper locking hook -3- using a screwdriver -2- -arrow a-. – Disengage other locking hooks -4- in the same way and turn VW emblem -1- in -direction of b-.
Page 274 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 3.3.2 Installing Carry out following work: – Push VW emblem -1- with locking hooks -2- into recesses in trim cover -3- -arrow a-. – Turn VW emblem -1- in -direction of arrow b- until the locking hooks -2- engage with the trim cover -3-.
Page 275 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Push trim cover with VW emblem -1- onto support -2-. – Press trim cover with VW emblem -1- onto support -2- until all locking hooks -arrows- engage.
Page 276: Rear Spoiler
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Rear spoiler Removing and installing rear spoiler Special tools and workshop equipment required ♦ Pull handle -V.A.G 1351/1- ♦ Cartridge gun -V.A.G 1628- ♦ Hot air blower -V.A.G 1416- ♦...
Page 277 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Materials Note Part numbers of the materials ⇒ Electronic parts catalogue “ET‐ KA” ♦ 1-component glass adhesive 1) 2) 3) ♦ Activator ♦ Glass primer/paint primer ♦...
Page 278 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Carry out following work: – Heat adhesive tape -2- on rear spoiler -1- with hot air blower -V.A.G 1416- . – Carefully detach adhesive tape between rear lid and rear spoiler (e.g.
Page 279 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Remove any adhesive residue of double-sided adhesive tape on rear lid with adhesive strip remover -VAS 6349- . – Cut back the remains of the adhesive sealing material to ap‐...
Page 280 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Remove any existing adhesive residue of adhesive tape using adhesive strip remover -VAS 6349- . ♦ Ensure that surfaces to be bonded are free of dust and grease.
Page 281 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Length of adhesive beads -1-: 50 mm (dimension -a-). ♦ Width of adhesive bead -1-: 6.5 mm (dimension -b-). ♦ Height of adhesive bead -1-: 7 mm.
Page 282: Mouldings And Trims
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Mouldings and trims Water deflector 5.1.1 Tools Special tools and workshop equipment required ♦ Setting gauge -3371- ♦ Hot air blower -V.A.G 1416- ♦ Adhesive strip remover -VAS 6349-...
Page 283 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 5.1.2 Assembly overview Note The right side is shown. The left side is similar. 1 - Water deflector 2 - Retaining strip Caution Only remove and install...
Page 284 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 5.1.3 Removing Carry out following work: – Lever out water channel -1- from retaining strip, starting from top -arrow-. – Gently heat up adhesive tape of retaining strip on front wing -2- using hot air gun -V.A.G 1416- and carefully pull off.
Page 285 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – If the gap at the retaining strip -1- deviates from the specifica‐ tion, the gap -arrows- must be adapted using for example, a plastic wedge -2- and hammer -3-.
Page 286 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 – Apply pressure to water channel -1- on inside -arrow a- so that it is easier to remove protective backing from front wing. – Pull off protective backing -2- in direction of -arrow b- and press water channel onto front wing firmly.
Page 287: Assembly Overview - Sill Panel Cover
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - sill panel cover Note Only the left side is shown. The right side is similar. 1 - Side member cover ❑ Removing –...
Page 288: Assembly Overview - B-Pillar Trim
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Assembly overview - B-pillar trim 1 - B-pillar trim 2 - Securing pins ❑ Part of trim. 3 - Clip 4 - Grommet ❑ Qty. 4.
Page 289: Removing And Installing B-Pillar Trim
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Removing and installing B-pillar trim 5.4.1 Removing Note The trim cannot be removed without being damaged. Carry out following work: – Press spreader pins -5- slightly into clips -3- -arrow a-.
Page 290: Side Member Extension "Gli
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 5.4.2 Installing Carry out following work: Note Check grommets -4- for damage and renew if necessary. – Place trim -1- against B-pillar. – Press trim securing pins -2- into grommets -4-.
Page 291 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 5.5.1 Removing Carry out following work: – Release locking tabs of clips -3- and remove clips from side member extension -1- as far as stop -arrow a-.
Page 292 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 5.5.2 Dimensions for securing screws Note Screws for side member extension are corrosion-resistant. No secondary treatment is required. ♦ If the screw is overtightened it is essential to replace it with a “black” oversize screw.
Page 293 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Note Dimension -a- is measured inclusive of front wheel housing liner; always measure other dimensions -b- to ♦ -e- from centre of hole. Dimension -f- is measured at centre hole.
Page 294 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 ♦ Working temperature is approx. 21°C. Carry out following work: • Holes (qty. 5) for securing screws -2- present. – Follow installation instructions ⇒ page 285 –...
Page 295: Lettering
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Lettering Tools Special tools and workshop equipment required ♦ Hot air blower -V.A.G 1416- ♦ Adhesive strip remover -VAS 6349- Installation instructions for lettering and...
Page 296: Lettering Dimensions
Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Lettering dimensions 6.3.1 Lettering for model name and engine designation Note When fitting the lettering, observe the fitting notes ⇒ page 287 Dimension -a- = 32 mm...
Page 297 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 6.3.2 Lettering for additional designation 1 - Right tail light in rear lid 2 - Designation of engine size 3 - Additional designation Maß a - 8 mm, from lower edge of engine designation to upper edge of additional designation Maß...
Page 298 Jetta 2011 ➤ , Jetta Hybrid 2013 ➤ General body repairs, exterior - Edition 08.2012 Rear lid lettering 1 - Right tail light in rear lid 2 - “Hybrid” lettering Maß a - 13 mm, from lower edge of tail light to upper edge of lettering Maß...

This manual is also suitable for:

Jetta hybrid 2013

Volkswagen Jetta 2011 Workshop Manual

Body - Front

Bonnet, Rear Lid

Front Doors, Door Components, Central Locking

Rear Doors, Door Components

Sunroof

Bumpers

Glazing

Exterior Equipment

Quick Links

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Summary of Contents for Volkswagen Jetta 2011