Page 1: Body Repairs
Service Body Repairs Jetta 2005 ➤ Edition 04.2009 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 © 2010 Volkswagen AG, Wolfsburg MEX5R006220...
Page 3 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Contents 00 - Technical data ........... .
Page 4 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing ............. .
Page 5 Jetta 2005 ➤ Body Repairs - Edition 04.2009 13.1 Removing ............. . 166 13.2...
Page 6 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Contents...
Page 7: Technical Data
Jetta 2005 ➤ Body Repairs - Edition 04.2009 00 – Technical data Vehicle identification data Vehicle identification number 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.
Page 8: Identification Plate
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Identification plate The identification plate -arrow- is located on the left B-pillar and is visible when the left front door is opened. Vehicle data sticker Rep. Gr.00 - Technical data...
Page 9 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. 1. Vehicle identification data...
Page 10: Safety Instructions
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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. Safety notes ⇒ General Information; Body Repairs, General Body Repairs ;...
Page 11: Moulded Foam Elements
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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.
Page 12: Laser Welding
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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.
Page 13: Galvanized Body Parts
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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.
Page 14: Floor Group
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Floor group The shaded body panels are not galvanized. The floor panel shown in this diagram serve only as orientation and consists of a body panel which is galvanized on both sides.
Page 15: High Strength Body Parts
Jetta 2005 ➤ Body Repairs - Edition 04.2009 High strength body parts Note Before carrying out body repairs observe the following information ⇒ General Information; Body Repairs, General Body Repairs . Body The shaded body panels are manufactured of high strength or very high strength body panels.
Page 16: Floor Group
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Floor group The shaded body panels are manufactured of high strength or very high strength body panels. The floor panel is only shown for orientation purposes. Rep. Gr.00 - Technical data...
Page 17 Jetta 2005 ➤ Body Repairs - Edition 04.2009 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.
Page 18: Body Panel Gaps/Shut Lines
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Body panel gaps/shut lines Note To adjust or check gaps, use special tool setting gauge ♦ -3371- . Gaps are always given in millimetres. ♦ Body - front Rep. Gr.00 - Technical data...
Page 19 Jetta 2005 ➤ Body Repairs - Edition 04.2009 7. Body panel gaps/shut lines...
Page 20: Body - Centre
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Body - centre Rep. Gr.00 - Technical data...
Page 21: Body - Rear
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Body - rear 7. Body panel gaps/shut lines...
Page 22 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Rep. Gr.00 - Technical data...
Page 23 Jetta 2005 ➤ Body Repairs - Edition 04.2009 7. Body panel gaps/shut lines...
Page 24: Body Dimensions
♦ 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 ♦...
Page 25 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,343 mm 8. Body dimensions...
Page 26 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,406 mm Rep. Gr.00 - Technical data...
Page 27 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,384 mm 8. Body dimensions...
Page 28 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,442 mm Dimension -b- = 881 mm Rep. Gr.00 - Technical data...
Page 29: Body - Centre
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Body - centre Dimension -a- = 885 mm Dimension -b- = 895 mm 8. Body dimensions...
Page 30 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 716 mm Dimension -b- = 965 mm Rep. Gr.00 - Technical data...
Page 31 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,424 mm 8. Body dimensions...
Page 32 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,430 mm Rep. Gr.00 - Technical data...
Page 33 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,392 mm 8. Body dimensions...
Page 34: Body - Rear
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Body - rear Dimension -a- = 1,280 mm Dimension -b- = 643 mm Rep. Gr.00 - Technical data...
Page 35 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,123 mm Dimension -b- = 549 mm 8. Body dimensions...
Page 36 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,424 mm Dimension -b- = 1,103 mm Rep. Gr.00 - Technical data...
Page 37: Floor Group - Front
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Floor group - front Dimension -a- = 828 mm Note Vehicle from below, line of vision is to rear. 8. Body dimensions...
Page 38 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,103 mm Note Vehicle from below, line of vision is to rear. Rep. Gr.00 - Technical data...
Page 39 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 619 mm Note Vehicle from below, line of vision is to rear. 8. Body dimensions...
Page 40: Floor Group - Centre
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Floor group - centre Dimension -a- = 1,455 mm Note This dimension is measured on the inside of the sill flange. ♦ Vehicle from below, line of vision is forwards. ♦ Rep. Gr.00 - Technical data...
Page 41 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,917 mm Note Vehicle from below, line of vision is forwards. 8. Body dimensions...
Page 42: Floor Group - Rear
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Floor group - rear Dimension -b- = 1,076 mm Note Vehicle from below, line of vision is forwards. Rep. Gr.00 - Technical data...
Page 43 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 985 mm Dimension -b- = 985 mm Note Vehicle from below, line of vision is forwards. 8. Body dimensions...
Page 44 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 1,043 mm Dimension -b- = 1,245 mm Note Vehicle from below, line of vision is forwards. Rep. Gr.00 - Technical data...
Page 45: Alignment Jig
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 ♦...
Page 46: Overview
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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...
Page 47: Front Alignment Bracket
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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 11 - Mounting point of gearbox suspension 9.
Page 48 Jetta 2005 ➤ Body Repairs - Edition 04.2009 2 - AB mounting for front part of longitudinal member 3 - Distance plate 4 - AB mounting for upper lon‐ gitudinal member Rep. Gr.00 - Technical data...
Page 49 Jetta 2005 ➤ Body Repairs - Edition 04.2009 10 - Straightening bracket mounting for engine mounting 11 - Straightening bracket mounting for gearbox mount‐ 9. Alignment jig...
Page 50 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 suspension strut 20 - Mounting point for rear locking of engine carrier Rep.
Page 51 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‐...
Page 52: Centre Alignment Bracket
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Centre alignment bracket 26 - Side member support point 28 - Mounting point of rear lon‐ gitudinal member 30 - Mounting point of axle sus‐ pension Rep. Gr.00 - Technical data...
Page 53 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 9. Alignment jig...
Page 54: Rear Alignment Bracket
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Rear alignment bracket 34 - Mounting point for front locking of rear suspension 36 - Mounting point of rear sus‐ pension strut 40 - Mounting point for rear locking of rear suspension...
Page 55 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...
Page 56: Portal Gauge
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 6240/5- ♦ Portal gauge -VAS 5007/25- 10.1.1...
Page 57 Jetta 2005 ➤ Body Repairs - Edition 04.2009 10.1.2 Rear door aperture Set up for portal gauge -VAS 5007/25- , front door aperture Detailed information on setting up the alignment bracket set can be found with the equipment. 10. Portal gauge...
Page 58: Renewing Right-Hand Bracket
Jetta 2005 ➤ Body Repairs - Edition 04.2009 50 – Body - front RO: 50 40 55 50 Renewing right-hand bracket WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Removing – Release original joint.
Page 59: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material. 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 .
Page 60 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in console, RP spot weld seam Rep. Gr.50 - Body - front...
Page 61: Renewing Left Console
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 40 55 56 Renewing left console WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions 2. Renewing left console...
Page 62: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Release original joint. – Release original joint. – Remove remaining material. Rep. Gr.50 - Body - front...
Page 63: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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‐...
Page 64: Renewing Retaining Bracket
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 43 55 00 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‐...
Page 65: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Release original joint. – Remove remaining material. Installing 3.2.1 Preparing new part Replacement part ♦ Front retaining bracket for subframe (spare part designation: retaining bracket subframe) – Drill holes for SG plug weld seam.
Page 66 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in new part, SG plug weld seam. Rep. Gr.50 - Body - front...
Page 67: Renewing Front Bumper Bracket
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 65 55 00 Renewing front bumper bracket WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Removing – Release original joint. 4. Renewing front bumper bracket...
Page 68: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Release original joint. – Release original joint. – Remove remaining material. Installing 4.2.1 Welding in Replacement part ♦ Front bumper bracket – Adapt new part to fit and secure in position with vehicle stand‐...
Page 69 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld front bumper bracket, SG continuous weld seam. – Weld front bumper bracket, SG continuous weld seam. 4. Renewing front bumper bracket...
Page 70: Renewing Upper Wheel Housing Longitudinal Member
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 72 55 00 Renewing upper wheel housing lon‐ gitudinal member WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions 1 - Upper longitudinal member...
Page 71: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Release original joint. – Release original joint. – Remove remaining material. Installing 5.2.1 Preparing new part Replacement part ♦ Upper inner wheel housing longitudinal member ♦ Upper outer wheel housing longitudinal member ♦...
Page 72 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.
Page 73: Renewing Upper Longitudinal Member For Wheel Housing - Partial Renewal
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 72 55 02 Renewing upper longitudinal mem‐ ber for wheel housing - partial renew‐ WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions 1 - Upper longitudinal member...
Page 74: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 170 mm – Release original joint. – Make parting cut on inner longitudinal member. – Release original joint. – Remove remaining material. Installing 6.2.1 Preparing new part Replacement part ♦...
Page 75 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Transfer parting cuts to new parts and cut out. 6.2.2 Welding in – Adapt new part to fit and secure in position with vehicle stand‐ ing on alignment bracket set .
Page 76: Renewing Front Wheel Housing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 74 55 50 Renewing front wheel housing WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Removing • Upper longitudinal member for wheel housing already re‐...
Page 77: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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 .
Page 78: Repairing Threads For Securing Subframe (Suspension Subframe)
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 79 49 50 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‐...
Page 79: Contents Of Thread Repair Kit
Jetta 2005 ➤ Body Repairs - Edition 04.2009 2 - Helicoil thread insert Contents of thread repair kit 1 - Twist drill ∅ 12.5 mm 2 - Thread-cutting tap M12 x 3 - Fitting spindle 4 - Thread insert M12 x 1.5 x...
Page 80: Repairing Thread
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Repairing thread 8.2.1 Drilling thread – Drill thread with a twist drill. Note Use drill -VAS 6267- when drilling and shaping. ♦ The drill must be held by an assistant using an additional hand ♦...
Page 81 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.
Page 82 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 / 4 turn further inwards.
Page 83: Renewing Front Longitudinal Member
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 79 55 03 Renewing front longitudinal member WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions 1 - Wheel housing 2 - Longitudinal member 3 - Make parting cut on longi‐...
Page 84: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Release original joint. Rep. Gr.50 - Body - front...
Page 85 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note 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.
Page 86: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimension -a- = 50 mm – Remove remaining material. Installing 9.2.1 Preparing new part Replacement part ♦ Longitudinal member Rep. Gr.50 - Body - front...
Page 87 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Transfer parting cut to new part and cut out. – Drill 7 mm ∅ holes for SG plug weld seam. 9.2.2 Welding in – Adapt new part to fit and secure in position with vehicle stand‐...
Page 88 Jetta 2005 ➤ Body Repairs - Edition 04.2009 9.2.3 Shortening new longitudinal member with cover plate Note 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.
Page 89 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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‐...
Page 90 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Secure front bumper bracket for front longitudinal member -1- using -RW 1- and -RW 3- in front of the longitudinal member -2-. Note There must be a gap of 1-2 mm between longitudinal member -2- with cover plate -3- and bumper bracket -1-.
Page 91: Renewing Front Longitudinal Member - Partial Replacement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 50 79 55 06 Renewing front longitudinal member - partial replacement WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions 1 - Cover plate 2 - Longitudinal member...
Page 92: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note Do not cut or weld 50 mm before or after the laser weld seam -1- (shaded area). 10.1 Removing – Make parting cuts as shown. – Release original joint. Rep. Gr.50 - Body - front...
Page 93: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material. 10.2 Installing 10.2.1 Preparing new part Replacement part ♦ Longitudinal member (subpart) ♦ Cover plate for longitudinal member – Transfer parting cuts to new parts and cut out.
Page 94 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Recreate original joint, RP spot weld seam. Note Distance between weld points -a- approx. 35-40 mm – Weld cover plate parting cut, SG continuous weld seam. 10.2.3 Shortening new longitudinal member with cover plate –...
Page 95: Renewing Roof
Jetta 2005 ➤ Body Repairs - Edition 04.2009 51 – Body - centre RO: 51 03 55 00 Renewing roof WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Special tools and workshop equipment required ♦...
Page 96: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Securing belt (commercial type) Removing 1 - Laser weld seam – Cut off roof roughly. Rep. Gr.51 - Body - centre...
Page 97: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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.
Page 98 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 B- Note Following repair sequence must be adhered to in order to en‐...
Page 99 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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).
Page 100 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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‐...
Page 101 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1.2.2 Adjusting roof depth By tightening and loosening the securing belts, you can determine dimension -a- to position roof deeper relative to roof side mem‐ bers. Dimension -a- = 3.5 + 0.5 mm...
Page 102 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Use a drill bit (∅ 3.5 mm) to check dimension -a- (drill bit -4- must be able to slide between roof -2- and securing belt -1- without much resistance). – If necessary, change felt pads -3- to adjust and improve roof alignment.
Page 103 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Cut approx. 2 mm off nozzle -B- to provide appropriate bead shape. – Apply 1-K installation adhesive -D 190 MKD A3- , using the pneumatic gun -V.A.G 1761/1- , onto the front roof cross mem‐...
Page 104 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Apply 1K assembly adhesive -D 190 MKD A3- -A- in area of roof member, using pneumatic cartridge gun -V.A.G 1761/1- . – Apply 1K 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- .
Page 105 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.
Page 106 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Check roof depth dimension -a- for the roof ⇒ “1.2.2 Adjusting roof depth”, page 95 Note After bonding, the vehicle must stand on a level surface for ♦ 8...10 hours at room temperature (at least 15° C) so that the bonding components are able to harden (hardening time).
Page 107 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – After painting, treat roof cavities -arrow- with cavity sealant - AKR 321 M15 4- . 1. Renewing roof...
Page 108: Renewing Front Roof Cross Member
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 07 55 50 Renewing front roof cross member WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Removing • Roof already removed ⇒ “1 Renewing roof”, page 89 –...
Page 109: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove residues at transition to left and right roof frame. Installing 2.2.1 Welding in Replacement part ♦ Front roof cross member – Fit new part and secure. – Check that roof is aligned correctly to the windscreen.
Page 110 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 Rep. Gr.51 - Body - centre...
Page 111: Renewing Roof Reinforcement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 08 55 50 Renewing roof reinforcement WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Removing • Roof already removed ⇒ “1 Renewing roof”, page 89 –...
Page 112: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove residues on left and right roof frame. Installing 3.2.1 Welding in Replacement part ♦ Roof reinforcement – Adapt roof reinforcement and secure. – Check fitting to roof. – Weld roof reinforcement to left and right roof frame, SG con‐...
Page 113: Renewing Rear Roof Cross Member
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 09 55 50 Renewing rear roof cross member WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Removing • Roof already removed ⇒ “1 Renewing roof”, page 89 –...
Page 114: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove residues at transition to left and right roof frame. Installing 4.2.1 Welding in Replacement part ♦ Rear roof cross member – Fit new part and secure. – Check that roof is aligned correctly to the rear window.
Page 115 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in new part, SG continuous weld seam (staggered). – Install roof ⇒ “1.2 Installing”, page 91 4. Renewing rear roof cross member...
Page 116: Renewing A-Pillar - Partial Renewal
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 37 55 00 Renewing A-pillar - partial renewal 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.
Page 117 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 4 - Bonded section 5. Renewing A-pillar - partial renewal...
Page 118: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing Note Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. – Make parting cuts -1- according to damage. – Release original joint. – Remove remaining material. Rep. Gr.51 - Body - centre...
Page 119: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove adhesive remains completely and grind adhesive surfaces back to bare metal. Installing 5.2.1 Preparing new part Replacement part ♦ A-pillar subpart with side member sealing plate ♦ Moulded foam element ♦...
Page 120 Jetta 2005 ➤ Body Repairs - Edition 04.2009 5.2.3 Welding in – Apply 2-K body adhesive -D 180 KD3 A2- in the area of the factory bonding and in the door aperture area. – Apply an adhesive cord -AKD 497 010 04 R10- above upper hinge area -1-.
Page 121 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. – Weld seam to reinforce A-pillar, SG plug weld seam and SG continuous weld seam (staggered).
Page 122: Renewing A-Pillar Reinforcement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 38 55 50 Renewing A-pillar reinforcement WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment. Therefore, refrain from using these processes.
Page 123 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - A-pillar reinforcement 2 - Front side member rein‐ forcement 3 - Moulded foam element Note 4 - Upper longitudinal member cover plate for wheel housing 6. Renewing A-pillar reinforcement...
Page 124: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Separate original joint of A-pillar reinforcement. – Separate bead of upper hinge reinforcement from interior. Rep. Gr.51 - Body - centre...
Page 125: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material. 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- –...
Page 126 Jetta 2005 ➤ Body Repairs - Edition 04.2009 6.2.3 Welding in – Apply 2-K body adhesive -D 180 KD3 A2- in the area of the door aperture. Note New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.
Page 127 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‐...
Page 128: Renewing B-Pillar
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 41 55 00 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.
Page 129 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 Upper B-pillar cut lines 7. Renewing B-pillar...
Page 130 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Outer B-pillar 2 - B-pillar reinforcement 3 - Inner B-pillar Rep. Gr.51 - Body - centre...
Page 131: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing Note 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-, ♦...
Page 132 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. Rep. Gr.51 - Body - centre...
Page 133: Installing
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.
Page 134 Jetta 2005 ➤ Body Repairs - Edition 04.2009 7.2.2 Marking area where no welding work may be carried out Note When welding in B-pillar, welding work must not be carried out in the areas marked on the illustrations for ♦...
Page 135 Jetta 2005 ➤ Body Repairs - Edition 04.2009 7.2.4 Welding in – Place backing plate behind side panel parting cut. Note Holes for door hinges in area -1- must remain free of adhesive. ♦ New part must be welded within 20 minutes, otherwise adhesive properties of adhesive will be impaired.
Page 136 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note Note that no welding work may be carried out in areas -1-. – Weld in B-pillar, RP spot weld seam. – Weld in parting cut, SG stepped weld seam. Rep. Gr.51 - Body - centre...
Page 137 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. 7. Renewing B-pillar...
Page 138: Renewing B-Pillar Reinforcement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 42 55 50 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.
Page 139 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 Note 8. Renewing B-pillar reinforcement...
Page 140: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing 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”.
Page 141 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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...
Page 142 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Separate remaining joint in door apertures. Note If the inner B-pillar is damaged excessively, then it must also be renewed. – Remove remaining material. Rep. Gr.51 - Body - centre...
Page 143: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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- –...
Page 144 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note The side member reinforcement and the B-pillar reinforcement may only be joined from above and below ♦ as shown in the -enlargements-, otherwise the strength of the B-pillar will be adversely affected. Welding the outer curvatures also weakens the construction.
Page 145 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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).
Page 146 Jetta 2005 ➤ Body Repairs - Edition 04.2009 8.2.2 Marking areas where no welding work may be carried out Note When welding in B-pillar reinforcement, welding work must not be carried out in areas marked on the illus‐ ♦ trations for “crash safety” reasons.
Page 147 Jetta 2005 ➤ Body Repairs - Edition 04.2009 8.2.4 Welding in Note New part must be welded-in within 20 minutes or adhesion properties of adhesive will be impaired. – In area -1- apply 2-K body adhesive -D 180 KD3 A2- (1 bead, ∅...
Page 148 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld upper part of parting cut of B-pillar reinforcement, SG continuous weld seam. – Weld upper B-pillar reinforcement, SG plug weld seam. Rep. Gr.51 - Body - centre...
Page 149 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld front -1- and rear -2- parting cuts, SG stepped weld seam. 8. Renewing B-pillar reinforcement...
Page 150 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note Note that no welding work may be carried out in areas -1-. – Recreate remaining joint, RP spot weld seam. – Install outer B-pillar ⇒ “7.2 Installing”, page 127 Rep. Gr.51 - Body - centre...
Page 151: Renewing Side Member
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 45 55 00 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.
Page 152 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Bonded section 2 - Moulded foam elements Note Rep. Gr.51 - Body - centre...
Page 153: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing Note 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. ♦ – Make parting cut -1- on A-pillar according to damage.
Page 154: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Release original joint to side member reinforcement. – 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.
Page 155 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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.
Page 156 Jetta 2005 ➤ Body Repairs - Edition 04.2009 9.2.3 Marking area where no welding work may be carried out Note When welding in side member, welding work must not be carried out in areas marked on the illustrations for ♦...
Page 157 Jetta 2005 ➤ Body Repairs - Edition 04.2009 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, ∅...
Page 158 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note 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. – Weld parting cut of side member to side panel, SG stepped weld seam.
Page 159 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. 9. Renewing side member...
Page 160: Renewing Side Member Reinforcement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 49 55 50 Renewing side member reinforce‐ ment (front) WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions • Side member already removed ⇒ “9 Renewing side member”, page 145...
Page 161 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - B-pillar reinforcement 2 - Side member reinforcement 3 - A-pillar 10. Renewing side member reinforcement...
Page 162: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 10.1 Removing – Make parting cut as shown (in front of the inner bulkhead). Dimension -a- = 300 mm – Release original joint. – Remove remaining material. Rep. Gr.51 - Body - centre...
Page 163: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 10.2 Installing 10.2.1 Preparing new part Replacement part ♦ Front side member reinforcement – Transfer parting cut to new part and cut it. – Drill holes for SG plug weld seam as shown, ∅ 10 mm.
Page 164 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld original joint, SG plug weld seam and RP spot weld seam. – Weld connection to web plate, SG plug weld seam. – Weld parting cut, SG continuous weld seam. – Install side member ⇒...
Page 165: Renewing Side Member Reinforcement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 49 55 52 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...
Page 166: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 11.1 Removing 1 - Inner side panel 2 - Wheel housing liner 3 - Cutting point – 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.
Page 167 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. – Check fitting to adjacent components. – Weld in rear side member reinforcement, RP spot weld seam.
Page 168: Renewing Seat Cross Member Mounting
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 69 55 56 Renewing seat cross member mounting (outer) WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Note If a thread in the mounting for the seat cross member is dam‐...
Page 169: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 12.1 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.
Page 170: Installing
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.
Page 171: Renewing Seat Cross Member Mounting
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 69 55 58 Renewing seat cross member mounting (on Tunnel) WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Note If a thread in the mounting for the seat cross member is damaged, the component must be replaced.
Page 172: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 13.1 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.
Page 173: Installing
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.
Page 174: Renewing Seat Cross Member
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 51 87 55 50 Renewing seat cross member (middle) WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions • Seat outer cross member mounting already removed ⇒...
Page 175: Removing
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 ♦...
Page 176: Renewing Cross Panel
Jetta 2005 ➤ Body Repairs - Edition 04.2009 53 – Body - rear RO: 53 05 55 00 Renewing cross panel WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Rep. Gr.53 - Body - rear...
Page 177: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Release original joint. 1. Renewing cross panel...
Page 178: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material. Installing 1.2.1 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 ⇒...
Page 179 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Drill holes into side panel for SG plug weld seam, ∅ 7 mm. 1. Renewing cross panel...
Page 180 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note 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.
Page 181 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note When welding tail light mounting with upper side panel use a “heat shield” to prevent damage to side panel paintwork. – Weld in cross panel, RP spot weld seam and SG plug weld seam.
Page 182 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1.2.3 Cutting out recesses for the tail light Note The left side of the vehicle is shown. The figure and the work apply analogously for the right side of the vehicle. – The dimensions for marking the recesses can be found in the table ⇒...
Page 183 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Dimensions for the recesses for the tail light. Dimension 26.6 15.0 105.0 20.0 30.0 – Check fitting to tail light and guide. Note To adjust the gaps for the tail light correctly, place washers be‐...
Page 184 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1.2.4 Installing welding bolts – Adapt the securing strip -1- to the cross panel. – Align the securing strip in the recess of the rear lid and secure Dimension a = 140 mm Dimension b = 9 mm Rep.
Page 185 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note 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 ♦...
Page 186 Jetta 2005 ➤ Body Repairs - Edition 04.2009 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.
Page 187 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note The welding bolts for the left guide -1- and the securing strip -2- are depicted. Building up weld studs on the right side of the vehicle is done analogously. – Weld the welding bolts for the guide -1- and the securing strip -2- onto the marked positions, butt weld.
Page 188: Renewing Mounting Plate
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 10 55 00 Renewing mounting plate WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions Rep. Gr.53 - Body - rear...
Page 189: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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 ⇒...
Page 190 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Drill holes, as shown, into side panel for SG plug weld seam, ∅ 7 mm. 2.2.2 Welding in – Fit new part and secure. – Check fit with add on parts.
Page 191 Jetta 2005 ➤ Body Repairs - Edition 04.2009 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.
Page 192: Renewing Luggage Compartment Floor
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 24 55 50 Renewing luggage compartment floor 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.
Page 193: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Separate original joint from above to the longitudinal mem‐ bers, the wheel housings and the exhaust pipe bracket. 3. Renewing luggage compartment floor...
Page 194 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Separate original joint from below to cross member for floor and to front floor panel. Rep. Gr.53 - Body - rear...
Page 195: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material. 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...
Page 196 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Drill holes for SG plug weld seam, ∅ 7 mm (distance approx. 20 mm). 3.2.2 Moulded foam elements Follow repair instructions. Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements 3.2.3...
Page 197 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Moulded foam elements – Weld in new part from above, SG plug weld seam and RP spot weld seam. 3. Renewing luggage compartment floor...
Page 198 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in new part from below, SG plug weld seam. – Install cross panel ⇒ “1.2 Installing”, page 172 Rep. Gr.53 - Body - rear...
Page 199: Renewing Longitudinal Member - Partial Renewal
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 47 55 50 Renewing longitudinal member - par‐ tial renewal WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions • Cross panel already removed ⇒...
Page 200: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Release original joint inside and outside. – Make parting cut as shown. Dimension -a- = 140 mm Dimension -b- = 50 mm – Remove remaining material. Rep. Gr.53 - Body - rear...
Page 201: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Installing 4.2.1 Preparing new part Replacement part ♦ Longitudinal member ♦ Exhaust pipe bracket – 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‐...
Page 202 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in new part, RP spot weld seam. – Weld parting cut all around, SG continuous weld seam. – Install luggage compartment floor ⇒ “3.2 Installing”, page 189 – Install cross panel ⇒...
Page 203: Renewing Rear Longitudinal Member End Piece
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 48 55 50 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 •...
Page 204: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Separate original joint on longitudinal member outer side. – Separate the SG continuous seam on the inner side of the longitudinal member. – Remove remaining material. Rep. Gr.53 - Body - rear...
Page 205: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Installing 5.2.1 Preparing new part Replacement part ♦ Longitudinal member ♦ Exhaust pipe bracket – Separate the longitudinal member end piece from the longitu‐ dinal member. 5.2.2 Welding in – Adapt new part to fit and secure in position with vehicle stand‐...
Page 206 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in new part, SG plug weld seam and SG continuous weld seam. – Install luggage compartment floor ⇒ “3.2 Installing”, page 189 – Install cross panel ⇒ “1.2 Installing”, page 172...
Page 207: Renewing Side Panel - Partial Replacement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 55 55 00 Renewing side panel - partial re‐ placement 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.
Page 208 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Moulded foam element Note 2 - Bonded section Rep. Gr.53 - Body - rear...
Page 209: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing Note Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. ♦ When making parting cut -2- keep overlap for replacement part in mind. ♦ Make parting cut -1- only on outer panel; do not damage internal reinforcements.
Page 210 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Grind through laser brazing seam. When doing this do not damage sealing channel underneath. – Separate original joint in rear window and from luggage com‐ partment -enlargement-. Rep. Gr.53 - Body - rear...
Page 211: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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.
Page 212 Jetta 2005 ➤ Body Repairs - Edition 04.2009 ♦ Moulded foam element ♦ 2K body adhesive -D 180 KD3 A2- ♦ Adhesive sealant -AKD 476 KD5 05- – Transfer parting cut to new part and cut out. – Drill holes on side panel as shown -enlargement- (in the area of the sealing channel at the bonding area ends) for SG plug weld seam, ∅...
Page 213 Jetta 2005 ➤ Body Repairs - Edition 04.2009 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-.
Page 214 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in side panel, RP spot weld seam. – Weld parting cuts, SG stepped weld seam. Rep. Gr.53 - Body - rear...
Page 215 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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.
Page 216: Renewing C-Pillar Reinforcement
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 29 55 50 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...
Page 217: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing 1 - Cutting point Note – Make parting cut as shown. – Release original joint. – Remove remaining material. 7. Renewing C-pillar reinforcement...
Page 218: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 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-).
Page 219: Renewing Outer Wheel Housing Liner
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 69 55 50 Renewing outer wheel housing liner 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 •...
Page 220 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Rep. Gr.53 - Body - rear...
Page 221: Removing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Removing – Separate original joint between inner wheel housing liner -1- and outer wheel housing liner -2- in luggage compartment and passenger compartment. 8. Renewing outer wheel housing liner...
Page 222 Jetta 2005 ➤ Body Repairs - Edition 04.2009 Note Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. – Separate original joint between inner side panel and C-pillar reinforcement of wheel housing from below. – Separate area to inner side member -1-.
Page 223: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 Installing 8.2.1 Welding in Replacement part ♦ Outer wheel housing liner ♦ 2K body adhesive -D 180 KD3 A2- Note New part must be welded-in within 20 minutes or adhesion prop‐ erties of adhesive will be impaired.
Page 224 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld outer wheel housing -2- to inner wheel housing -1- in luggage compartment and passenger compartment, RP spot weld seam. Rep. Gr.53 - Body - rear...
Page 225 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – 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 –...
Page 226: Renewing Spare Wheel Well - Partial Renewal
Jetta 2005 ➤ Body Repairs - Edition 04.2009 RO: 53 80 55 50 Renewing spare wheel well - partial renewal WARNING Observe safety notes! ⇒ General Information; Body Repairs, General Body Repairs ; Safety instructions • Cross panel already removed ⇒...
Page 227: Installing
Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Remove remaining material. – Place floor panel body side. Installing 9.2.1 Preparing new part Replacement part ♦ Rear floor panel 9. Renewing spare wheel well - partial renewal...
Page 228 Jetta 2005 ➤ Body Repairs - Edition 04.2009 1 - Cutting point – Transfer parting cut -1- to the new part and cut -shaded area- (when doing this take 10 mm additional material for overlap into considera‐ tion). – Drill holes for SG plug weld seam, ∅...
Page 229 Jetta 2005 ➤ Body Repairs - Edition 04.2009 – Weld in spare wheel recess, SG plug weld seam. – Install cross panel ⇒ “1.2 Installing”, page 172 9. Renewing spare wheel well - partial renewal...

Volkswagen Jetta 2005 Body Repair Manual

Quick Links

Body Repairs

Related Manuals for Volkswagen Jetta 2005

Summary of Contents for Volkswagen Jetta 2005

Table of Contents