Volkswagen Jetta 2005 Workshop Manual
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Volkswagen Jetta 2005 Workshop Manual

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Service
Workshop Manual
Golf Variant 2007 ➤
Jetta 2005 ➤
General body repairs, exterior
Edition 10.2009
Service Department. Technical Information

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Summary of Contents for Volkswagen Jetta 2005

  • Page 1 Service Workshop Manual Golf Variant 2007 ➤ Jetta 2005 ➤ General body repairs, exterior Edition 10.2009 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 MEX5R005620...

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Contents 50 - Body - front ............
  • Page 4 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Tools ..............
  • Page 5 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - door assembly ......... . 103 Assembly overview - door hinges .
  • Page 6 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.17 Removing and installing carrier unit ......... . 174 1.18...
  • Page 7 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Tools ..............249 Repairing bumper cover .
  • Page 8 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.10 Removing and installing window regulator ........305 Rear door window (Variant) .
  • Page 9 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Lettering ..............357 Tools .

  • Page 10: Golf Variant 2007 ➤ , Jetta

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 viii Contents...

  • Page 11: Body - Front

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 50 – Body - front Lock carrier Tools Special tools and workshop equipment required ♦ Guide pins -T10093- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- 1.

  • Page 12: Assembly Overview - Lock Carrier, Service Position

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - lock carrier, service position 1 - Lock carrier with add-on parts ❑ Removing and installing ⇒ page 4 ❑ Service position ⇒ page 2 2 - Bolt ❑...
  • Page 13 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Attach special tool guide pins -T10093- to left and right longi‐ tudinal members. – Remove bolts -2- on left and right from upper part of lock car‐...

  • Page 14: Removing And Installing Lock Carrier With Add-On Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note Ensure that the charge air cooler pressure hoses are properly ♦ engaged again. Hoses and lines must not be pinched. ♦ If necessary, replenish coolant ⇒ Rep. Gr. 19 ; Removing and ♦...
  • Page 15 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note Do not hang condenser and hydraulic oil cooler from lines. ♦ Do not kink lines for condenser and hydraulic systems. ♦ 1.4.2 Installing Install in reverse order of removal.

  • Page 16: Wing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Wing Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. Gr.50 - Body - front...

  • Page 17: Assembly Overview - Front Wing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - front wing Note Only the left side is shown. The right side is similar. 1 - Wing ❑ Removing and installing ⇒ page 7 2 - Bolt ❑...

  • Page 18: Removing And Installing Wing Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Loosen hexagon nut -6- and remove bolts -2-. – Pull out foam element -3- between wing and longitudinal mem‐ ber and remove wing -1-.
  • Page 19 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -2- and remove wing bracket -1-. 2.4.2 Installing – Install wing bracket -1-. Specified torque for bolts -2-: 6 Nm. Wing and wing bracket must be aligned with bonnet and bumper cover ⇒...

  • Page 20: Noise Insulation

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Noise insulation Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. Gr.50 - Body - front...

  • Page 21: Assembly Overview - Noise Insulation

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - noise insulation Note The removal and installation procedures may have to be modified slightly depending on engine fitted. 1 - Noise insulation ❑...

  • Page 22: Underbody Cladding

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Underbody cladding Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. Gr.50 - Body - front...

  • Page 23: Assembly Overview - Underbody Cladding

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - underbody cladding Note Only the left side is shown. The right side is similar. 1 - Underbody cladding ❑ -Arrow- points forwards ❑...

  • Page 24: Assembly Overview - Rear Underbody Cladding

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear underbody cladding 1 - Bolt ❑ Qty. 3 ❑ 2 Nm 2 - Rear underbody cladding ❑ Installed only on right side.

  • Page 25: Plenum Chamber Bulkhead

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Plenum chamber bulkhead Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Assembly overview - plenum chamber bulkhead 1 - Plenum chamber bulkhead 2 - Hexagon nut ❑...

  • Page 26: Bonnet, Rear Lid

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 55 – Bonnet, rear lid Bonnet Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Removal lever -80-200- Rep. Gr.55 - Bonnet, rear lid...

  • Page 27: Assembly Overview - Bonnet

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bonnet 1 - Bonnet ❑ Removing and installing ⇒ page 17 ❑ Adjusting ⇒ page 25 2 - Adjustment buffer ❑ Qty. 2 ❑...
  • Page 28 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Now remove hexagon nuts -1- and lift bonnet -5- out of bonnet hinges -3-. 1.3.2 Installing Install in reverse order of removal. Specified torque for bonnet hexagon nut: 22 Nm.

  • Page 29: Removing Gas Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing gas strut – Open bonnet and support it. – Position a small screwdriver beneath spring clip -2-. – Raise spring clip -2- until it can be moved over ball socket in direction of -arrow-.

  • Page 30: Removing And Installing Insulation

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.6.1 Removing – Remove front bonnet ⇒ page 17 – Remove bolts -2- and remove bonnet hinge -1-. 1.6.2 Installing – Install lid hinge -1-.
  • Page 31 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull insulation -2- out of elongated holes. 1.7.2 Installing – Push insulation -2- underneath gas strut and place assembly tongues in elongated holes. – Engage all retaining clips -1- in insulation -2-.
  • Page 32 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 When installing insulation -2- ensure that retaining clips -1- are fitted with wider side outwards. Rep. Gr.55 - Bonnet, rear lid...

  • Page 33: Assembly Overview - Bonnet Latch And Release Components

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bonnet latch and release components 1 - Arrester ❑ To remove, unbolt bolts ⇒ Item 2 (page 23) ❑ Adjustment is carried out by moving arrester to left or right in elonga‐...

  • Page 34: Disconnecting Bowden Cable

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Disconnect connector -5- for bonnet contact switch -F266- . The connector is secured over the right headlight. – Unclip wiring for bonnet contact switch -F266- on lock carrier -3-.

  • Page 35: Adjusting Bonnet

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.11 Adjusting bonnet For initial adjustment of bonnet, -1-, the vehicle must be standing on the ground and the arrester be removed. – Remove latch hook -9- ⇒...
  • Page 36 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – After adjusting bonnet -1-, install and adjust arrester ⇒ Item 1 (page 23) 1.11.1 Adjusting bonnet lock If gaps change when bonnet is closed, minor corrections can be made via bonnet lock and arrester.

  • Page 37: Removing And Installing Release Lever

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Now loosen bolts -1- to correct or adjust gaps at front of bonnet ⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions . Specified torque for bolts -1-: 12 Nm.
  • Page 38 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.12.2 Installing – Slide clip -2- completely into release lever -1-. – Then press release lever -1- onto mounting in mounting brack‐ et and fasten release lever.

  • Page 39: Rear Lid (Saloon)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear lid (saloon) Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- Assembly overview - rear lid 1 - Hinge cover 2 - Wiring harness 3 - Rear lid ❑...

  • Page 40: Removing And Installing Rear Lid

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 11 - Bolt ❑ Qty. 2 ❑ 23 Nm 12 - Locking wedge ❑ Removing and installing ⇒ page 32 13 - Pop rivet nut 14 - Base for registration plate ❑...

  • Page 41: Releasing Gas From Gas Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Position a small screwdriver beneath spring clip -2-. – Raise spring clip -2- until it can be moved over ball socket in direction of -arrow-.

  • Page 42: Removing And Installing Striker Pin

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -1- and remove lid hinge -2-. 2.6.2 Installing Install in reverse order of removal. Specified torque for lid hinge bolts: 22 Nm Adjust rear lid ⇒...

  • Page 43: Adjusting Rear Lid

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Adjusting rear lid Note Vehicle must be standing on the ground to perform the basic ♦ adjustment of the rear lid. The rear lid lock is bolted directly to the rear lid. It does not ♦...
  • Page 44 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Adjust detent slide to dimension -a- = 12.5 mm. – Close rear lid to detent position with light pressure at centre of lid. – Open rear lid again.

  • Page 45: Assembly Overview - Lid Lock And Lock Cylinder Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - lid lock and lock cylinder carrier 1 - Bowden cable ❑ From lid lock to lock cyl‐ inder 2 - Connector ❑ For bonnet lock 3 - Bowden cable ❑...

  • Page 46: Removing And Installing Handle Trim

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Disconnect connections -1- on lock cylinder. – Unhook Bowden cable -2-. – Remove nuts -3- and remove lock cylinder -4-. 2.10.2 Installing Install in reverse order of removal.

  • Page 47: Rear Lid Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove cover cap -1-. – Disconnect connector -2- from lid lock -5-. – Unhook Bowden cable -3-. – Remove remove hexagon nuts -4- and remove lid lock -5-.

  • Page 48: Removing And Installing Rear Lid Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.14 Removing and installing rear lid seal 2.14.1 Removing – Pull rear lid seal -1- off body flange. 2.14.2 Installing – Align rear lid seal -1- so that the vulcanised point -arrow- is located to the middle of the left tail light cluster.

  • Page 49: Rear Lid (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear lid (Variant) Tools Special tools and workshop equipment required ♦ Torque wrench 5…50 Nm -V.A.G 1331- Assembly overview - rear lid 1 - Rear lid ❑...

  • Page 50: Removing And Installing Rear Lid

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 10 - Registration plate light ❑ Removing and installing ⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - exterior 11 - Rear window wiper ❑...

  • Page 51: Removing And Installing Gas Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Install bolts -3-. – Guide electrical wiring -5- through opening in rear lid and se‐ cure bellows -1-. – Adjust rear lid ⇒ page 44 and tighten bolts -3-, specified tor‐...

  • Page 52: Releasing Gas From Gas Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Releasing gas from gas strut – Clamp gas strut in vice in area marked -x- = 50 mm. WARNING Clamp gas strut only within area -x-; otherwise danger of ac‐...
  • Page 53 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.6.2 Installing – Position hinge -3- in vehicle. – Screw nuts -2- onto studs -1-. – Install rear lid ⇒ page 40 – Align hinge to rear lid.

  • Page 54: Adjusting Rear Lid

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Adjusting rear lid Note Vehicle must be on the ground to carry out rear lid adjustment. ♦ The rear lid lock -2- is bolted directly to the rear lid -1-. It does not have elongated holes, so it cannot be ♦...
  • Page 55 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Rear lid can be adjusted within oversized holes of hinge -3- by loosening nut -2-. – Rear lid can be adjusted slightly at bolts -3-.
  • Page 56 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Loosen bolts -1-. – Move striker pin -2- to upper position and tighten bolts -1-. – Close rear lid and check adjustment. The rear lid is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or does not stand proud and all contours align when the rear lid is closed.

  • Page 57: Removing And Installing Release Button

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Press cover -4- onto adjustment buffer. Removing and installing release button 3.8.1 Removing – Remove rear lid trim ⇒ General body repairs, interior; Rep.

  • Page 58: Removing And Installing Lid Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Disconnect connector -3- from connection on release button -1-. – Unscrew the two nuts -2- from studs for release button and take cover -4- off upwards.
  • Page 59 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 The rear lid can be opened using emergency release -4- for elec‐ trical malfunctions. Emergency release is accessible through an aperture in rear lid trim.

  • Page 60: Rear Lid Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Before closing rear lid, check function of lid release components. 3.10 Rear lid seal During production a sealant is applied to the rear lid seals, the seal is then placed on the body flange and rolled on.

  • Page 61: Removing And Installing Rear Lid Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.11 Removing and installing rear lid seal 3.11.1 Removing – Pull rear lid seal -1- off body flange -2-. 3.11.2 Installing – Align rear lid seal -1- so that vulcanised point -arrow- faces centre of left tail light.
  • Page 62 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Push seal -1- evenly onto body flange -2-. Rep. Gr.55 - Bonnet, rear lid...

  • Page 63: Registration Plate Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.12 Registration plate carrier 1 - Pop rivet nut ❑ Qty. 2 2 - Registration plate carrier ❑ Assignment ⇒ Parts catalogue“ETKA” 3 - Bolt ❑...

  • Page 64: Fuel Tank Flap Unit (Saloon)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Fuel tank flap unit (saloon) Assembly overview - tank flap unit 1 - Fuel filler neck 2 - Tank flap unit ❑ Removing and installing ⇒...
  • Page 65 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull rubber part of tank flap unit -2- off fuel tank filler neck -1-. – Pull tank flap unit -2- with drain hose -3- to rear and swing fuel tank flap unit out of side panel.

  • Page 66: Removing And Installing Tank Filler Flap Locking Motor V155

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Specified torque for bolt -4-: 1.5 Nm – Perform functional check of release components. Removing and installing tank filler flap locking motor -V155- 4.3.1 Removing –...
  • Page 67 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull tank filler flap locking motor -V155- -9- together with re‐ lease rod -7- out of seal -6- and fitting -5-. 4.3.2 Installing Install in reverse order of removal.

  • Page 68: Fuel Tank Flap Unit (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Fuel tank flap unit (Variant) Assembly overview - tank flap unit 1 - Fuel filler neck 2 - Tank flap unit ❑ Removing and installing ⇒...
  • Page 69 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 5.2.2 Installing – Feed drain hose -3- through aperture in tank flap unit -2- and pull drain hose through as far as possible. – Guide drain hose into side panel.

  • Page 70: Removing And Installing Tank Filler Flap Locking Motor V155

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Perform functional check of release components. Removing and installing tank filler flap locking motor -V155- 5.3.1 Removing – Remove tank flap unit ⇒ page 58 –...
  • Page 71 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull service cover -B- forwards slightly. – Disconnect connector -2- on tank filler flap locking motor - V155- -1- through opening in side panel.
  • Page 72 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 5.3.2 Installing – Feed wiring harness -3- through opening in side panel. – Secure rubber grommet -4- on side panel. – Reconnect connector -2-. – Slide tank filler flap locking motor -V155- -1- in opposite direc‐...

  • Page 73: Front Doors, Door Components, Central Locking

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 57 – Front doors, door components, central locking Front door Tools Special tools and workshop equipment required ♦ Socket -T10072- ♦ Assembly tool -T10118- ♦ Door alignment tool -3320-...

  • Page 74: Materials

    3) Materials are stored in box -D 004 700- . Assembly overview - door assembly A new door concept has been introduced with Jetta 2005 ▸, Bora 2005 ▸. The door consists of an inner part -6- and an outer panel -1-.
  • Page 75 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 The retaining rails are bolted to the inner part of the door and bonded to the outer panel of the door. The inner part -6- of the door functions basically as the previously known assembly carrier.

  • Page 76: Assembly Overview - Door Hinges

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 8 - Bolt ❑ Feature: bolt with pointed end and thicker washer ❑ Qty. 1 in area of front section of door shoulder ❑ 10 Nm 9 - Insulation ❑...
  • Page 77 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note The right side is shown. The left side is similar. ♦ The hinge bolts must always be renewed if loosened. ♦ Hinges are now one piece.

  • Page 78: Removing And Installing Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 11 - Multi-point socket head bolt ❑ 20 Nm + / 4 turn further (90°). ❑ Always renew after loosening 12 - Multi-point socket head bolt ❑...
  • Page 79 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull door in direction of -arrow- off guide bolts -2- and -9-. 1.5.2 Installing Install in reverse order of removal. Specified torque for bolts -4-, -5- and -11-: 20 Nm + / 4 turn further (90°).

  • Page 80: Adjusting Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Observe front door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions . Adjusting door Caution Nut of eccentric bolt -9- should not be loosened under any cir‐...
  • Page 81 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Observe front door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions . To be able to adjust gaps correctly, bolts -5-, -7-, -11- and -12- on A-pillar must be loosened.
  • Page 82 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 The following can be adjusted at the striker pin: ♦ When the front door does not align with the rear door. – Loosen striker pin -1- by unbolting bolts -2- on B-pillar.

  • Page 83: Removing And Installing Outer Panel On Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing outer panel on door 1.7.1 Removing – Prise out clips -3-, starting at bottom of door -1-, and remove cover -2-. 1. Front door...
  • Page 84 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove lock cylinder ⇒ page 86 – Remove door handle ⇒ page 86 – Remove bolt -1- from bearing bracket -2- which is located be‐...
  • Page 85 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.7.2 Installing Caution Bolts of different types are used to secure outer panel of door. If these are fitted in the wrong positions, the outer panel for the door will be damaged.

  • Page 86: Installing New Outer Panel On Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Specified torque for bolt -2-: 10 Nm Specified torque for bolt -3-: 14 Nm Specified torque for bolt -4-: 10 Nm Further installation is performed in reverse order of removal...
  • Page 87 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Install front -2- and rear -6- retaining rails on inner part of door -1-. Use “bolt with no point but with thicker washer” for this.
  • Page 88 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Check gap/shut lines using setting gauge -3371- ⇒ Body Re‐ pairs; Rep. Gr. 00 ; Body dimensions . If gap dimension cannot be adjusted further, door inner part must be adjusted ⇒...
  • Page 89 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Fixing blocks -2- from assembly tool set -T10237- are required when fitting outer panel on door. Two strips of double-sided ad‐ hesive tape -5- are applied on the contact surface.

  • Page 90: Removing And Installing Retaining Rail On Door Outer Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing retaining rail on door outer panel 1.9.1 Removing retaining rail Caution The following work steps are to be carried out with great care.
  • Page 91 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 • Door outer panel with retaining rails is removed ⇒ page 73 – Place door outer panel -1- on firm surface and protect door outer panel against scratches.

  • Page 92: Installation Notes For Bonding A New Outer Panel On Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Secure outer panel for door on new retaining rail with fixing blocks from assembly tool set -T10237- and double-sided ad‐ hesive tape. 1.10 Installation notes for bonding a new out‐...

  • Page 93: Cleaning Off Excess Adhesive Sealing Material

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 What is meant by minimum curing period is, time from bonding outer panel on door to time vehicle is taken into use or further work is carried out. During this time, the vehicle must stand on a level surface at room temperature (at least 15 °C).

  • Page 94: Assembly Overview - Door Inner Part

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.13 Assembly overview - door inner part Note The right side is shown. The left side is similar. 1 - Door inner part 2 - Window slot seal...

  • Page 95: Assembly Overview - Door Handle And Door Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.14 Assembly overview - door handle and door lock Note Only the left side is shown. The right side is similar. 1 - Cable ❑ To lock release from in‐...

  • Page 96: Removing And Installing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 14 - Torx bolt ❑ 4.5 Nm 1.15 Removing and installing housing Note The removal and installation sequence is only for the right hous‐ ing. The removal and installation of the right lock cylinder is similar.
  • Page 97 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.16.1 Removing – Remove housing ⇒ page 86 – Lever clip -2- out of door handle -1-. – Swivel door handle -1- out of door -arrow-.
  • Page 98 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden cable to the door handle later. – Swivel door handle -1- into door.

  • Page 99: Removing And Installing Bearing Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.17 Removing and installing bearing bracket Note Removal and installation are described only for the right bearing bracket. The removal and installation of the left bearing bracket is similar.

  • Page 100: Removing And Installing Door Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.17.2 Installing – Push bearing bracket -1- with guide pins -2- in mountings -3-. – Secure retaining rubber -4- to guide pins and securing bolts on bearing plate mounting.
  • Page 101 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bearing bracket ⇒ page 89 – Disconnect connector -5-. – Remove bolts -6-. – Release cable -1- from relay lever -8- and remove door lock -4-.

  • Page 102: Assembly Overview - Side Impact Protection

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.19 Assembly overview - side impact protection 1 - Side impact protection ❑ To remove and install, remove outer panel for door ⇒ page 112 2 - Bolt ❑...

  • Page 103: Removing And Installing Door Inner Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.21 Removing and installing door inner seal Note The removal and installation sequence is only for the right door inner seal. The removal and installation of the left door inner seal is similar.

  • Page 104: Removing And Installing Door Outer Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Start installing door inner seal at top radius -arrow a- of door aperture. 1.22 Removing and installing door outer seal Note Removal and installation are described only for the right door ♦...
  • Page 105 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.22.1 Removing – Pull door outer seal off door. 1.22.2 Installing – Remove adhesive residues with erasure disc of adhesive strip remover -VAS 6349- .
  • Page 106 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull off protective foil and install seal on door. Do not pull door outer seal excessively to avoid stretching seal. – Press complete bonding surface of seal -3- onto door -1- all around using roller -3356- .
  • Page 107 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1. Front door...

  • Page 108: Central Locking

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Central locking Fitting location overview - central locking components 1 - Anti-theft alarm horn ❑ Location: under rear section of wheel hous‐ ing liner in front right wheel housing (remov‐...
  • Page 109 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 9 - Tank filler flap locking motor -V155- ❑ Location: behind right trim of luggage compartment ❑ Removing (saloon) ⇒ page 54 ❑ Removing (Variant) ⇒...

  • Page 110: Adapting Keys With Remote Control

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Adapting keys with remote control Keys with remote control are adapted using the vehicle diagnosis, testing and information system -VAS 5051- . – Select “guided fault finding” in vehicle diagnostic, testing and information system -VAS 5051- .

  • Page 111: Removing And Installing Battery For Folding Key With Remote Control

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing battery for fold‐ ing key with remote control 2.4.1 Removing – Insert a screwdriver in slot between transmitter unit -1- and key -2-.

  • Page 112: Rear Doors, Door Components

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 58 – Rear doors, door components Rear door (saloon) Tools Special tools and workshop equipment required ♦ Socket -T10072- ♦ Assembly tool -T10118- ♦ Door alignment tool -3320-...

  • Page 113: Materials

    6) Materials are stored in box -D 004 700- . Assembly overview - door assembly A new door concept has been introduced with Jetta 2005 ▸, Bora 2005 ▸. The door consists of an inner part -6- and an outer panel -1-.
  • Page 114 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 The retaining rails are bolted to the inner part of the door and bonded to the outer panel of the door. The inner part -6- of the door functions basically as the previously known assembly carrier.

  • Page 115: Assembly Overview - Door Hinges

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 9 - Insulation ❑ Self-adhesive ❑ To bond, first heat the insulation and then press on firmly 10 - Clip ❑ Qty. 5 11 - Window slot seal ❑...
  • Page 116 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note The right side is shown. The left side is similar. ♦ The hinge bolts must always be renewed if loosened. ♦ Hinges are now one piece.

  • Page 117: Removing And Installing Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 13 - Multi-point socket head bolt ❑ 20 Nm + / 4 turn further (90°). ❑ Always renew after loosening Removing and installing door Note The removal and installation sequence is only for the right door.
  • Page 118 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull door -1- in direction of -arrow- off guide bolts -2- and -9-. 1.5.2 Installing Install in reverse order of removal. Specified torque for bolts -4-, -5- and -11-: 20 Nm + / 4 turn further (90°).

  • Page 119: Adjusting Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Observe rear door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions . Adjusting door Caution Nut of eccentric bolt -9- should not be loosened under any cir‐...
  • Page 120 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Observe rear door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions . To be able to adjust gaps correctly, bolts -6-, -7-, -11- and -12- must be loosened.
  • Page 121 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ♦ When rear door does not align with side panel. – Loosen striker pin -1- by loosening bolts -2- on side panel. – Adjust rear door at striker pin -1- so that rear door is flush with rear side panel when shut (wind noise).

  • Page 122: Removing And Installing Outer Panel On Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing outer panel on door 1.7.1 Removing – Prise out clips -3-, starting at bottom of door -1-, and remove rear cover -2-.
  • Page 123 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove housing ⇒ page 124 – Remove door handle ⇒ page 125 – Remove bolt -1- from bearing bracket -2- which is located be‐...
  • Page 124 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.7.2 Installing Caution Bolts of different types are used to secure outer panel of door. If these are fitted in the wrong positions, the outer panel for the door will be damaged.

  • Page 125: Installing New Outer Panel On Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Further installation is performed in reverse order of removal Installing new outer panel on door Caution Bolts of different types are used to secure outer panel of door.
  • Page 126 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Fit two guide bolts -4- in lower edge of door inner part -1-. The painted outer panel for the door is first offered up without bonding agent.
  • Page 127 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove door outer panel again. – Apply a bead of adhesive material -2- using cartridge gun - V.A.G 1628- to front -1- and rear -3- retaining rails.
  • Page 128 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Fixing blocks -2- from assembly tool set -T10237- are required when fitting outer panel on door. Two strips of double-sided ad‐ hesive tape -5- are applied on the contact surface.

  • Page 129: Removing And Installing Retaining Rail On Door Outer Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing retaining rail on door outer panel 1.9.1 Removing retaining rail Caution The following work steps are to be carried out with great care.
  • Page 130 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 • Door outer panel with retaining rails is removed ⇒ page 112 – Place door outer panel -1- on firm surface and protect door outer panel against scratches.

  • Page 131: Installation Notes For Bonding A New Outer Panel On Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Secure outer panel for door on new retaining rail with fixing blocks from assembly tool set -T10237- and double-sided ad‐ hesive tape. 1.10 Installation notes for bonding a new out‐...

  • Page 132: Cleaning Off Excess Adhesive Sealing Material

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 For door outer panel: curing period for 1K adhesive -DH 009 100 01- is 90 minutes and for 2K adhesive -DA 004 600 A2- 180 mi‐...

  • Page 133: Assembly Overview - Door Inner Part

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.13 Assembly overview - door inner part Note The right side is shown. The left side is similar. 1 - Window slot seal 2 - Insulation ❑...

  • Page 134: Assembly Overview - Door Handle And Door Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.14 Assembly overview - door handle and door lock Note The right side is shown. The left side is similar. 1 - Door lock ❑ Removing and installing ⇒...

  • Page 135: Removing And Installing Door Handle

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.15.1 Removing – Prise rear cover ( ⇒ page 112 Fig. M58-0054, item 2) off rear door. – Lever out caps in front of bolts -1-.
  • Page 136 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.16.2 Installing – Guide assembly tool -T10118- into door through opening in door outer panel. – Use a hand torch to illuminate inside of door for improved vis‐...

  • Page 137: Removing Bearing Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Swivel door handle -1- into door. – Pull clip -2- in the panel opening and engage clip in door han‐ dle -1- -arrow-. Note Press door handle -1- against door panel when assembling.
  • Page 138 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull bearing bracket -1- with guide pins -2- out of mountings -3-. 1.17.2 Installing – Push bearing bracket -1- with guide pins -2- in mountings -3-.

  • Page 139: Removing And Installing Door Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Further installation is performed in reverse order of removal. 1.18 Removing and installing door lock Note The removal and installation sequence is only for the right door lock.
  • Page 140 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bearing bracket ⇒ page 127 – Separate connector -4-. – Remove bolts -6-. – Release cable -3- from relay lever -5- and remove door lock -1-.

  • Page 141: Assembly Overview - Side Impact Protection

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.19 Assembly overview - side impact protection 1 - Side impact protection ❑ To remove and install, remove outer panel for door ⇒ page 112 2 - Bolts ❑...

  • Page 142: Removing And Installing Door Inner Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.21 Removing and installing door inner seal Note The removal and installation sequence is only for the right door inner seal. The removal and installation of the left door inner seal is similar.

  • Page 143: Removing And Installing Door Outer Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Start installing door inner seal at top radius -arrow a- of door aperture. 1.22 Removing and installing door outer seal Note Removal and installation are described only for the right door ♦...
  • Page 144 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.22.1 Removing – Pull door outer seal -1- off door -2-. 1.22.2 Installing – Remove adhesive residues with erasure disc of adhesive strip remover -VAS 6349- .
  • Page 145 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull off protective backing and start fitting seal in upper radius -arrow a- of door. Do not pull door outer seal excessively to avoid stretching seal.
  • Page 146 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rep. Gr.58 - Rear doors, door components...

  • Page 147: Rear Door (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear door (Variant) Note The rear doors of the Variant are of a different concept when compared with the rear doors of the saloon. The door outer panel is no longer removable.

  • Page 148: Assembly Overview - Rear Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear door 1 - Door ❑ Removing and installing ⇒ page 140 ❑ Adjusting door ⇒ page 142 2 - Door handle with base ❑...
  • Page 149 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note The right side is shown. The left side is similar. ♦ The hinge bolts must always be renewed if loosened. ♦ Hinges are now one piece.

  • Page 150: Removing And Installing Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ❑ Always renew after loosening 13 - Multi-point socket head bolt ❑ 20 Nm + / 4 turn further (90°). ❑ Always renew after loosening Removing and installing door 2.4.1...
  • Page 151 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull door -1- in direction of -arrow- off guide bolts -2- and -9-. 2.4.2 Installing Install in reverse order of removal. Specified torque for bolts -4-, -5- and -11-: 20 Nm + / 4 turn further (90°).

  • Page 152: Adjusting Door

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Observe rear door gap/shut lines ⇒ Body Repairs; Rep. Gr. 00 ; Body dimensions . Adjusting door Caution Nut of eccentric bolt -9- should not be loosened under any cir‐...
  • Page 153 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 To be able to adjust gaps correctly, bolts -6-, -7-, -11- and -12- must be loosened. Other measures such as raising the door have no effect. Subse‐...

  • Page 154: Assembly Overview - Assembly Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Loosen striker pin -1- by loosening bolts -2- on side panel. – Adjust rear door at striker pin -1- so that rear door is flush with rear side panel when shut (wind noise).

  • Page 155: Removing And Installing Assembly Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ⇒ page 317 Removing and installing assembly car‐ rier Note The removal and installation sequence is only for the right as‐ sembly carrier. The removal and installation of the left assembly carrier is similar.
  • Page 156 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Lever out caps -5-. – Lower door window -1- until spreader pin -3- and spreader plug -4- are accessible in cut-out of window regulator.
  • Page 157 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Guide wire -3- in door. – Remove assembly carrier -1- with door lock -2- from door in direction of -arrow-. 2. Rear door (Variant)
  • Page 158 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.7.2 Installing Install in reverse order of removal. – Secure door window ⇒ page 310 – Specified torque for assembly carrier bolt -arrow-: 8 Nm...
  • Page 159 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Specified torque for door lock bolt -2-: 18 Nm 2. Rear door (Variant)

  • Page 160: Assembly Overview - Door Handle And Door Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - door handle and door lock Note The right side is shown. The left side is similar. 1 - Door lock ❑ Removing and installing ⇒...

  • Page 161: Removing And Installing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing housing Note Removal and installation sequence is only for right housing. Re‐ moval and installation of left housing is similar. 2.9.1 Removing –...
  • Page 162 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.10.1 Removing – Remove housing ⇒ page 151 – Lever clip -2- out of door handle -1-. – Swivel door handle -1- out of door -arrow-.
  • Page 163 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note Hooking the spring into the operating lever secures the lock. This prevents incorrect attachment of the Bowden cable to the door handle later. – Swivel door handle -1- into door.

  • Page 164: Removing And Installing Bearing Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.11 Removing and installing bearing bracket 2.11.1 Removing Note Removal and installation are described only for the right bearing bracket. The removal and installation of the left bearing bracket is similar.

  • Page 165: Removing And Installing Door Lock

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.12 Removing and installing door lock Note The removal and installation sequence is only for the right door lock. The removal and installation of the left door lock is similar.

  • Page 166: Removing And Installing Door Inner Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.14 Removing and installing door inner seal Note The removal and installation sequence is only for the left door inner seal. The removal and installation of the right door inner seal is similar.

  • Page 167: Removing And Installing Door Outer Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Start installing door inner seal at top radius -arrow a- of door aperture. 2.15 Removing and installing door outer seal Note Removal and installation are described only for the right door ♦...
  • Page 168 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.15.1 Removing – Pull door outer seal -1- off door -2-. 2.15.2 Installing – Remove adhesive residues with erasure disc of adhesive strip remover -VAS 6349- .
  • Page 169 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull off protective backing and start fitting seal in upper radius -arrow a- of door. Do not pull door outer seal excessively to avoid stretching seal.
  • Page 170 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rep. Gr.58 - Rear doors, door components...

  • Page 171: Sunroof

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 60 – Sunroof Sliding/tilting sunroof with glass pan‐ el (Meritor) Tools Special tools and workshop equipment required ♦ Roller for door insulation foil -3356- ♦ Front end hook -3370- ♦...
  • Page 172 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Opening sliding/tilting sunroof to the so called comfort position, prevents to a large extent wind noise while driving, which can oc‐ cur when sunroof is fully open.

  • Page 173: Assembly Overview - Sliding/Tilting Sunroof With Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - sliding/tilting sunroof with glass panel 1 - Glass panel for sliding/tilting sunroof (single pane safety glass) ❑ Removing and installing ⇒ page 166 ❑...

  • Page 174: Removing And Installing Bellows

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ❑ Qty. 3 ❑ 3.5 Nm 13 - Crank for emergency operation ❑ Hexagon key is located in vehicle tool kit 14 - Electric drive ❑...
  • Page 175 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bellows -1-. 1.4.2 Installing – Slide sliding headlining to rear. – Run sliding/tilting sunroof glass panel to tilted position. – Fit bellows -1- first at top rear -2-.

  • Page 176: Removing And Installing Sliding/Tilting Sunroof Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Hook in bellows -1- at bottom front and clip in bellows in lower part of guide plate -3-. Removing and installing sliding/tilting sunroof glass panel 1.5.1...

  • Page 177: Adjusting Height Of Sliding/Tilting Sunroof Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -1- on left and right. – Remove sliding/tilting sunroof glass panel -2- out upwards. Caution The guide plate must not moved to “Open” position when re‐...

  • Page 178: Adjusting Panel Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bellows ⇒ page 164 – Loosen sliding/tilting sunroof glass panel -2- securing bolts -1- on left and right (do not remove). – Run sliding/tilting sunroof glass panel to “open” position.

  • Page 179: Renewing Panel Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – If the pressure is too great, roof seal -1- can be pushed to‐ gether all round by rolling with roller -3356- . Renewing panel seal –...

  • Page 180: Removing And Installing Sliding Headliner

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Insert front-end hook -3370- between edge of roof and wind deflector bearing -arrow-. – Pull wind deflector bearings out of detents on left and right, in direction of -arrow-, using front-end hook -3370- .

  • Page 181: Removing And Installing Sliding/Tilting Sunroof Glass Panel Drive

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.10.2 Installing Install in reverse order of removal. Finally carry out a functional check. 1.11 Removing and installing sliding/tilting sunroof glass panel drive 1.11.1 Removing –...

  • Page 182: Adjusting Drive For Sliding/Tilting Sunroof Glass Panel (0 Position)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Finally carry out a functional check. 1.12 Adjusting drive for sliding/tilting sunroof glass panel (0 position) There may be a requirement to adjust the zero (0) position if the drive was removed when not in the zero position or the sliding/ tilting sunroof glass panel was opened or closed using the emer‐...

  • Page 183: Adjusting Parallel Running

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 The mark -arrow- on the rear of the guide upper section -1- must, on both sides, lie within the marks dimension -a- on the guide plate -2-.

  • Page 184: Assembly Overview - Carrier Unit

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.16 Assembly overview - carrier unit 1 - Carrier unit ❑ Removing and installing ⇒ page 174 2 - Bolt ❑ Qty. 12 ❑ 8 Nm...
  • Page 185 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 not removed) ⇒ General body repairs, interior; Rep. Gr. 70 ; Roof trims . – Pull water drain hoses -arrows- off carrier unit -1-. – Separate connector -3- on sliding/tilting sunroof glass panel drive -4-.
  • Page 186 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Carrier unit must not contact roof frame. – Install bolts -2-. – Check routing of wiring and connectors of electrical consum‐ ers in roof and correct as necessary.

  • Page 187: Operating Without Current

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.18 Operating without current Note In the event of power failure, the sliding/tilting sunroof with glass panel can be moved using a hexagon key directly on the drive.

  • Page 188: Removing And Installing Guide Plate

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Slide front guide -2- forwards and pull guide plate -1- in -direction of arrow- out of front guide -2-. 1.19.2 Installing Install in reverse order of removal.

  • Page 189: Cleaning Water Drain Hoses

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Slide rear guide lower part -1- in -direction of arrow- in guide rail -3-, until the locating hook guide locking mechanism -2- is released.
  • Page 190 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.21.1 Front water drain hoses The front water drain hoses run through the A-pillars and end at the bulkhead cross member. Cleaning is done from the sunroof panel aperture.
  • Page 191 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.21.2 Rear water drain hoses The rear water drain hoses run through the C-pillars and end in the rear wheel housings. Cleaning is done from the wheel hous‐...

  • Page 192: Panorama Sliding Sunroof (Arvin-Meritor)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Panorama sliding sunroof (Arvin- Meritor) Tools Special tools and workshop equipment required ♦ Roller for door insulation foil -3356- ♦ Torque wrench -V.A.G 1783- ♦ Adhesive strip remover -VAS 6349-...

  • Page 193: Establishing Reference Points Of Panorama Sliding Roof

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Opening of front glass panel can be preselected using rotary switch -1-. Opening glass panel to the so called comfort position -4-, pre‐ vents to a large extent wind noise while driving, which can occur when roof is fully open.

  • Page 194: Assembly Overview - Panorama Sliding Roof

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Press sun blind closing button -3- and hold during whole standardization run (approx. 20 s) in this position. – When establishing reference points, sun blind first closes and then moves approx.

  • Page 195: Removing And Installing Front Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing front glass pan‐ 2.5.1 Removing – Open glass panel -1- until trim -2- is accessible. – Unclip locking lugs -3- by pressing together in direction of -arrow A- on back.
  • Page 196 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -2- from glass panel -1- on left and right. Note To remove bolts, use a magnetic tool so that bolts do not fall into mechanism of panorama sliding roof.

  • Page 197: Removing And Installing Rear Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing rear glass pan‐ 2.6.1 Removing Note To remove bolts, use a magnetic tool so that bolts do not fall into mechanism of panorama sliding roof.

  • Page 198: Adjusting Height Of Front And Rear Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Fit glass panel -1- from top into roof. – Install spacer -2- and tighten bolt -3- (5 Nm). – Pull inner seal -3- slightly backwards at -arrow- positions and screw bolts -2- without tightening them.
  • Page 199 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Checking height adjustment – Check adjustment of front glass panel -1- and rear glass panel -2- with a depth gauge. ♦ Dimension -a- = 1.5 ± 1 mm ♦...

  • Page 200: Renewing Seals For Rear Glass Panel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull inner seal -3- slightly backwards at -arrow- positions and remove bolts -2- of rear glass panel -1-. – Adjust rear glass panel -2- as shown in illustration.

  • Page 201: Renewing Outer Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove side seal -2- from profile of rear glass panel -1-. – Remove existing adhesive residue using adhesive strip re‐ mover -VAS 6349- .
  • Page 202 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull out outer seal -1- in bonding area -3- from roof -2-. – Cut off all round profile of outer seal -1- in -arrow- area, flush with edge of roof -4-.

  • Page 203: Renewing Inner Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Centre new outer seal -1- with butt -arrow- on rear centre of roof cut-out. – Pull protective backing from adhesive tape -3- of new outer seal -1- and press seal on roof -2-.
  • Page 204 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Using a screwdriver, unclip securing clip -3- over mounting bracket -2- of wind deflector -1-. – Using a screwdriver, unclip mounting bracket -2- of wind de‐...

  • Page 205: Removing And Installing Wind Deflector Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note Wind deflector mounting bracket must engage audibly. ♦ Securing clip of mounting bracket must always be renewed ♦ after removal. 2.12 Removing and installing wind deflector bracket 2.12.1...

  • Page 206: Removing And Installing Preselector For Glass Panel And Sun Blind

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.13 Removing and installing preselector for glass panel and sun blind – Removing preselector for panorama sliding roof glass panel ⇒ Electrical system; Rep. Gr. 96 ; Lights and switches in roof trim .
  • Page 207 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Carefully detach ribbon cable -3- (if fitted) from web -1- and pull it to side -arrow-. To access right bolt -4- of sliding sunroof motor -2- with tool, drill a 10 mm ∅...

  • Page 208: Removing And Installing Sun Blind Motor

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.14.2 Installing With front glass panel removed: – Pull tilting mechanism fully forwards on both sides until it is completely lowered. – Push tilting mechanism on -arrow- areas of slider -2- not on guide plate -3-.

  • Page 209: Removing And Installing Sun Blind

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.15.2 Installing – Before installing motor, adjust sun blind by ensuring parallel distance -a- between sun blind cross strut -1- and sun blind housing -2-.
  • Page 210 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Carefully lift sun blind cross strut -3- with sun blind slide -1-. Note Ensure that sun blind fabric -2- is not damaged. – Pull sun blind slide -1- in direction of -arrow- on side of sun blind cross strut -3-.
  • Page 211 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Carefully pull sun blind cross strut -1- in direction of -arrow- out of beading -3- of sun blind fabric -2-. – Carefully slide sun blind cross strut -1- on beading -3-.
  • Page 212 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Lug -3- of sun blind housing -2- must be inserted under sun blind rail -1-. – Push sun blind slide -1- in direction of -arrow- into sun blind cross strut -4-.

  • Page 213: Assembly Overview - Assembly Frame

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Specified torques Sun blind housing bolt 3.5 Nm Cover cap bolt 2 Nm Note After installation, sun blind synchronism and ease of operation should be checked. To do this, move by hand sun blind drive on motor using a commercially available hexagon key and avoid wrinkling and deformation of sun blind fabric.

  • Page 214: Installing And Removing Motor Plate And Sun Blind Cable

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.18 Installing and removing motor plate and sun blind cable 2.18.1 Removing – Remove moulded headliner ⇒ General body repairs, interior; Rep. Gr. 70 ; Roof trims .
  • Page 215 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull sun blind cables -3- out of discharge tubes -1- and motor plate -4-. – Using an appropriate screwdriver -5-, lever motor plate -5- out of rear part -6-.
  • Page 216 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Lever guide tube -1- out of cable support bracket -4- of rear part -3-. – Remove cable -2- from sun blind rail -5-. 2.18.2 Installing Install in reverse order of removal.

  • Page 217: Removing And Installing Assembly Frame

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.19 Removing and installing assembly frame 2.19.1 Removing Note A second mechanic is required for removing and installing as‐ sembly frame. – Remove moulded headliner ⇒ General body repairs, interior;...
  • Page 218 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull off water drain hoses from connections -arrows- of as‐ sembly frame -1-. – Disconnect connector to wiring harness of sliding sunroof mo‐ tor -8-.

  • Page 219: Removing And Installing Rear Part

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – First tighten letter marked bolts -2- in alphabetic order to 8 Nm. – Tighten then remaining bolts -2- of assembly frame -1- to 8 Nm.
  • Page 220 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull inner seal -2- off assembly frame -1-. – Remove sun blind ⇒ page 199 – Loosen wiring harness from rear part. – Remove bolts -2- from guide rail -1-.
  • Page 221 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.20.2 Installing – Remove existing adhesive residue using adhesive strip re‐ mover -VAS 6349- . – Clean bonding surfaces on rear part and guide rails with clean‐...

  • Page 222: Removing And Installing Front Motor Plate

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.21 Removing and installing front motor plate 2.21.1 Removing – Remove assembly frame from vehicle ⇒ page 207 – Remove sliding sunroof motor ⇒ page 196 –...
  • Page 223 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull ends of cable -1- out of motor plate -2-. – Using appropriate screwdriver -4-, lever motor plate -2- out of front part -3-.
  • Page 224 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.21.2 Installing Note Insert motor plate -2- into front part -3-. ♦ Do not grease motor plate and cables -1-. ♦ Further installation is performed in reverse order of removal.

  • Page 225: Removing And Installing Tilting Mechanism And Front Glass Panel Cable

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.22 Removing and installing tilting mecha‐ nism and front glass panel cable 2.22.1 Removing – Remove front glass panel ⇒ page 185 – Remove rear glass panel ⇒...
  • Page 226 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.22.2 Installing Note Guide rails must only be cleaned if heavily soiled. ♦ To do this, use cleaner -D 009 401 04- . ♦ Then grease guide rail in guide areas with lithium grease -G ♦...

  • Page 227: Maintenance And Care

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.23 Maintenance and care No regular maintenance is usually required for the panorama sliding roof. If cleaning is necessary because it is heavily soiled, use cleaner -D 009 401 04- .

  • Page 228: Sun Blind

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Carefully detach ribbon cable -5- (if fitted) from web -1-. – Pull ribbon cable to side -arrow- using a commercially availa‐ ble hexagon key -4- until access is made possible through hole in web -1-.

  • Page 229: Cleaning Water Drain Hoses

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Insert hexagon key -2- into bolt of sun blind motor -1-. When turning by hand, greater force is necessary since motor is not uncoupled from drive.
  • Page 230 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.25.1 Front water drain hoses The front water drain hoses run through the A-pillars and end at the bulkhead cross member. Cleaning is done from panorama sliding roof cut-out.
  • Page 231 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.25.2 Rear water drain hoses The rear water drain hoses run through the D-pillars and end in the rear wheel housings. Cleaning is done from the wheel hous‐...

  • Page 232: Bumpers

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 63 – Bumpers Front bumper Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1332- Repairing bumper cover...

  • Page 233: Assembly Overview - Bumper Cover

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bumper cover 1 - Bolt ❑ 2 Nm 2 - Bolt ❑ 3.5 Nm 3 - Cover ❑ Material PP/EPDM ❑ Removing and installing ⇒...
  • Page 234 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -4- and -1- (point upwards) on left and right in area of wheel housing liner. Further dismantling requires the assistance of a second mechan‐...

  • Page 235: Front Bumper Cover Add-On Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Front bumper cover add-on parts 1 - Bumper cover ❑ Material PP/EPDM ❑ Removing and installing ⇒ page 223 2 - Left bumper strip ❑ Material PP/EPDM ❑...
  • Page 236 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.5.1 Removing and installing air intake grille Removing Note The removal and installation sequence is only for the left side. Removal and installation of the right side is similar.

  • Page 237: Front Bumper Cover Substructure Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Front bumper cover substructure parts 1 - Right guide ❑ Bolted to bumper carrier ❑ To remove, unbolt bolts ⇒ Item 9 (page 227) 2 - Expanding nut ❑...

  • Page 238: Assembly Overview - Bumper Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bumper carrier 1 - Bumper carrier 2 - Bolt ❑ Qty. 4 on each side ❑ 60 Nm 3 - Bolt ❑ Qty. 6 ❑...

  • Page 239: Front Bumper, Cup Edition

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Front bumper, Cup Edition Front bumper cover 2.1.1 Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1332- 2.1.2...
  • Page 240 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.1.3 Assembly overview - front bumper cover 1 - Front bumper cover ❑ Material PUR/MF 17 ❑ Removing ⇒ page 231 ❑ Installing ⇒ page 232 2 - Bolt ❑...
  • Page 241 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.1.4 Removing – Remove left and right side marker lights -5- ⇒ Electrical sys‐ tem; Rep. Gr. 92 ; Removing and installing side marker lights in from bumper .
  • Page 242 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.1.5 Installing – With help of a second mechanic, install front bumper cover -1- on lock carrier ensuring it remains parallel with vehicle Note When positioning front bumper cover -1-, ensure it is parallel to wing.
  • Page 243 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.1.6 Front bumper cover add-on parts 1 - Front bumper cover ❑ Material PUR/MF 17 ❑ Removing ⇒ page 231 ❑ Installing ⇒ page 232 2 - End plate ❑...
  • Page 244 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.1.7 Front bumper cover substructure parts 1 - Right guide ❑ Bolted to bumper carrier ❑ To remove, unbolt bolts ⇒ Item 9 (page 234) 2 - Expanding nut ❑...
  • Page 245 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.1.8 Assembly overview - front bumper carrier 1 - Front bumper carrier 2 - Bolt ❑ Qty. 4 on each side ❑ Specified torque: 60 Nm 3 - Bolt ❑...

  • Page 246: Rear Bumper (Saloon)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper (saloon) Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1331- Repairing bumper cover Note If bumper cover is damaged, determine whether plastic can be repaired before renewing bumper.

  • Page 247: Assembly Overview - Bumper Cover

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bumper cover 1 - Bolt ❑ Qty. 1 on each side ❑ Bolted from luggage compartment (to re‐ move, remove luggage compartment side cov‐...
  • Page 248 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – From luggage compartment, remove bolt -1- on left and right (remove luggage compartment side covers ⇒ General body repairs, interior; Rep. Gr. 70 ; Luggage and load compartment trim .

  • Page 249: Rear Bumper Cover With Add-On Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper cover with add-on parts 1 - Bumper cover ❑ Material PP/EPDM ❑ Removing and installing ⇒ page 237 2 - Spoiler ❑ Material PC/ABS ❑...

  • Page 250: Rear Bumper Cover Substructure Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper cover substructure parts 1 - Securing strip 2 - Hexagon nut ❑ Qty. 4 ❑ 2 Nm 3 - Guide ❑ Left and right 4 - Hexagon nut ❑...

  • Page 251: Assembly Overview - Bumper Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bumper carrier 1 - Bumper carrier 2 - Bolt ❑ Qty. 3 on each side ❑ 20 Nm 3 - Foam element ❑...

  • Page 252: Rear Bumper, Saloon, Cup Edition

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper, saloon, Cup Edition Rear bumper cover, saloon 4.1.1 Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1331- ♦...
  • Page 253 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.1.3 Assembly overview - rear bumper cover 1 - Bolt ❑ Left and right ❑ Specified torque: 8 Nm 2 - Bolt ❑ Specified torque: 5 Nm 3 - Spreader rivet ❑...
  • Page 254 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.1.4 Removing – Remove luggage compartment side trim ⇒ General body re‐ pairs, interior; Rep. Gr. 70 ; Trims; Luggage and load com‐ partment .
  • Page 255 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Disconnect connectors from all electrical components. 4.1.5 Installing – With the help of a second mechanic, guide rear bumper cover parallel into left and right guides.
  • Page 256 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.1.6 Rear bumper cover add-on parts 1 - Rear bumper cover ❑ Material PP/EPDM ❑ Removing ⇒ page 244 ❑ Installing ⇒ page 245 2 - Spoiler ❑...
  • Page 257 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.1.7 Rear bumper cover substructure parts 1 - Securing strip 2 - Hexagon nut ❑ Qty. 4. ❑ Specified torque: 2 Nm 3 - Guide ❑...
  • Page 258 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.1.8 Assembly overview - rear bumper carrier 1 - Rear bumper carrier 2 - Bolt ❑ Qty. 3 on each side ❑ Specified torque: 20 Nm 3 - Foam element ❑...

  • Page 259: Rear Bumper (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper (Variant) Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Torque wrench -V.A.G 1331- Repairing bumper cover Note If bumper cover is damaged, determine whether plastic can be repaired before renewing bumper.

  • Page 260: Assembly Overview - Bumper Cover

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bumper cover 1 - Bolt ❑ Qty. 7 ❑ 5 Nm 2 - Spreader rivet ❑ Qty. 1 on each side 3 - Bumper cover ❑...
  • Page 261 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Further dismantling requires the assistance of a second mechan‐ – Pull bumper cover -3- parallel out of guide profiles with help of a second mechanic.
  • Page 262 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rep. Gr.63 - Bumpers...

  • Page 263: Rear Bumper Cover With Add-On Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper cover with add-on parts 1 - Bumper cover ❑ Material PP/EPDM ❑ Removing and installing ⇒ page 250 2 - Reflector ❑ Engaged in bumper...

  • Page 264: Rear Bumper Cover Substructure Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear bumper cover substructure parts 1 - Securing strip 2 - Nut ❑ Qty. 4 ❑ 2 Nm 3 - Nut ❑ Qty. 1 on each side ❑...

  • Page 265: Assembly Overview - Bumper Carrier

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - bumper carrier 1 - Bumper carrier 2 - Bolt ❑ Qty. 5 ❑ 20 Nm 3 - Foam element ❑ USA versions only...

  • Page 266: Assembly Overview - Towing Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - towing bracket 1 - Bolt ❑ Sealing plugs ❑ Qty. 3 ❑ Specified torque: 20 Nm DANGER! The bolts -1- function as plugs and seal the pas‐...
  • Page 267 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -4-. 5.9.2 Installing Install in reverse order of removal. DANGER! The bolts -1- function as plugs and seal the passenger com‐ partment against exhaust fumes, and must without exception be installed.
  • Page 268 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Bolt -4-: 50 Nm + turn 90° + 30° further Rep. Gr.63 - Bumpers...

  • Page 269: Glazing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 64 – Glazing Flush bonded windows Tools Special tools and workshop equipment required ♦ Removal kit for flush bon‐ ded windows - V.A.G 1474 A- ♦...

  • Page 270: Materials

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ♦ Electric cutter - V.A.G 1561 A- ♦ Cutting blade - V.A.G 1561/2- ♦ Scraping blade - V.A.G 1561/8- ♦ Cutter (offset) - V.A.G 1561/10- ♦...

  • Page 271: Assembly Overview - Windscreen

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ♦ Cleaning solution -D 009 401 04- ♦ Primer applicator -D 009 500 25- ♦ Adhesive remover -D 002 000 10- ♦ Cutting cord -357 853 999- ⇒...

  • Page 272: Assembly Overview - Plenum Chamber Cover

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - plenum chamber cover 1 - Plenum chamber cover ❑ Only pull out of wind‐ screen seal by hand ❑ Removing and installing ⇒...
  • Page 273 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Beginning on right, carefully pull plenum chamber cover -1- upwards out of windscreen seal -5-. 1.5.2 Installing plenum chamber cover Caution Striking the plenum chamber cover can cause cracks in the windscreen.

  • Page 274: Removing And Installing Windscreen

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note An insert is installed in windscreen seal of new windscreens. Remove this insert before installing plenum chamber cover. Removing and installing windscreen 1.6.1 Removing windscreen –...
  • Page 275 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Slide cover -V.A.G 1474/8- between windscreen -1- and dash panel. – Thrust awl -V.A.G 1474/2- -2- through adhesive bead. – Pull cutting cord -3- through adhesive sealing material into in‐...

  • Page 276: Assembly Overview - Rear Window (Saloon)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear window (saloon) 1 - Rear window ❑ Removing and installing ⇒ page 266 2 - Rear lid 3 - PUR adhesive sealant ❑...
  • Page 277 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull cutting cord through adhesive sealing material into inside of vehicle using awl -V.A.G 1474/2- . – Pull the other end of the cord through into the interior and counterhold using handle -V.A.G 1351/1- .
  • Page 278 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove roof end strip ⇒ General body repairs, interior; Rep. Gr. 70 ; Roof trims . – Remove rear shelf ⇒ General body repairs, interior; Rep. Gr.

  • Page 279: Assembly Overview - Rear Window (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear window (Variant) 1 - Rear window ❑ Removing and installing ⇒ page 269 2 - Rear lid 3 - PUR adhesive sealant ❑...
  • Page 280 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull off connector -1- for heated rear window -arrow- and press connecting tabs onto window. – Pull cutting cord -1- through adhesive sealing material at lower radius of rear window and into inside of vehicle using awl - V.A.G 1474/2- from removal kit for flush bonded windows -...

  • Page 281: Assembly Overview - Side Window (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Cover flange -2- all round with textile-reinforced adhesive tape. – Cut through adhesive sealing material (with remains of win‐ dow) in window aperture using electric cutter -V.A.G 1561 A- and blade -V.A.G 1561/10- (with stop roller).

  • Page 282: Removing Undamaged Side Window (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.12 Removing undamaged side window (Variant) Note The removal and installation sequence is only for the right side window. The removal and installation of the left side window is similar.

  • Page 283: Removing Broken Side Window (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Insert cutting cord -3- behind seal in window flange with aid of tube -1-. – Secure one end of cord -2- to pull handle -V.A.G 1351/1- -2- to counterhold.

  • Page 284: Preparing Old Undamaged Window For Glazing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.15 Preparing old undamaged window for glazing Note If installing an undamaged window, cut back residual adhesive ♦ seal to 1...2 mm, being careful not to damage primer and ce‐...

  • Page 285: Touching Up Paint Damage

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Now apply primer -4- evenly in one motion using applicator - D 009 500 25- -3- to the previously cleaned area -1- of window.

  • Page 286: Installation Instructions

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.19 Installation instructions – Apply adhesive material to primed area -1- or to trimmed seal‐ ant bead, holding double cartridge gun -VAS 5237- at right angle to window.

  • Page 287: Cleaning Off Excess Adhesive Sealing Material

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.22 Cleaning off excess adhesive sealing material – Use of adhesive remover -D 002 000 10- as a cleaning solution is recommended. Observe the appropriate safety precautions when performing this work.

  • Page 288: Front Door Windows

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Front door windows Tools Special tools and workshop equipment required ♦ Roller -T10314- ♦ Torque wrench -V.A.G 1783- Rep. Gr.64 - Glazing...

  • Page 289: Assembly Overview- Front Door Window

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview- front door window Note The right side is shown. The left side is similar. ♦ The bolt -4- is accessible from interior and exterior. From exterior the bolt has a right-hand thread. This ♦...
  • Page 290 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.3.1 Removing Note The bolt -3- is accessible from interior and exterior. From exterior the bolt has a right-hand thread. This means: from exterior the bolt is removed by turning it to left, from interior the bolt is removed by turning it to right.
  • Page 291 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Loosen bolts -3- (do not remove) from inside by turning to right and press clamping jaws apart. – Lift rear of door window -1- and swivel out of door forwards, in direction of -arrow-.

  • Page 292: Adjusting Door Window

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.3.2 Installing – Insert door window -1- in door in -direction of arrow-. Ensure that door window -1- is properly located in window chan‐ nels.
  • Page 293 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Loosen bolts -3- (do not remove) from inside by turning to right and press clamping jaws apart. – Applying light pressure press door window -1- in clamping jaws in -direction of arrow- and align door window tension free at rear window channel.

  • Page 294: Assembly Overview - Window Regulator Motor

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - window regulator motor Note The right side is shown. The left side is similar. 1 - Window regulator motor ❑ Removing and installing ⇒...
  • Page 295 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.6.1 Removing – Removing front door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim . – Secure door window against sliding down with adhesive tape.
  • Page 296 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Run window regulator twice in each direction to upper and lower stops. This initiates and readies the window regulator motor and activates the roll-back function.

  • Page 297: Assembly Overview - Window Channel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - window channel Note The right side is shown. The left side is similar. ♦ For a better representation the illustration is drawn without door outer panel.
  • Page 298 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.8.1 Removing – Removing front door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim . – Remove exterior mirror ⇒ page 331 –...

  • Page 299: Removing And Installing Window Channel Trim Strip

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Note To prevent wind noise, ensure window channel seats evenly when installing. Removing and installing window chan‐ nel trim strip 2.9.1 Removing – Push window channel -1- in top rear area slightly to side.
  • Page 300 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Press trim strip -1- evenly in direction of -arrow- into window channel -2- by hand. – Then press window channel -2- fully into mounting of trim strip -1- with roller -T 10314- .

  • Page 301: Assembly Overview - Window Regulator

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.10 Assembly overview - window regulator Note The right side is shown. The left side is similar. 1 - Window regulator ❑ Removing and installing ⇒...
  • Page 302 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Removing door window ⇒ page 279 – Remove bolts -2- from mounting plate -5-. – Remove bolts -3- for window regulator. – Remove window regulator -1- with drive -4- and mounting plate -5- for window regulator motor from inner part of door.

  • Page 303: Rear Door Window (Saloon)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear door window (saloon) Tools Special tools and workshop equipment required ♦ Release tool -T10236- ♦ Roller -T10314- ♦ Torque wrench -V.A.G 1783- 3. Rear door window (saloon)

  • Page 304: Assembly Overview - Rear Door Window

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear door window Note The right side is shown. The left side is similar. 1 - Door window ❑ Removing and installing ⇒...
  • Page 305 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.3.1 Removing Note When door outer panel has been removed the spreader pin and spreader plug to remove door window are accessible from exte‐ rior.
  • Page 306 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull door window upwards -arrow- out of window slot. 3.3.2 Installing Note When installing door window, always renew spreader plug and ♦ spreader pin.

  • Page 307: Assembly Overview - Door With Fixed Window With Window Channel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - door with fixed window with window channel Note The right side is shown. The left side is similar. 1 - Window channel ❑...
  • Page 308 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.5.1 Removing – Remove door outer panel ⇒ page 112 – Removing door window ⇒ page 294 – Pull window channel -4- out of middle frame -1- and guide window channel inwards.
  • Page 309 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.5.2 Installing Install in reverse order of removal. Specified torque for bolts -2- on middle frame: 5.5 Nm Specified torque for bolts -3- on middle frame: 4.5 Nm...

  • Page 310: Removing And Installing Window Channel Trim Strip

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing window chan‐ nel trim strip 3.6.1 Removing – Push window channel -1- in top front area slightly to side. – Remove spreader rivet -5-.
  • Page 311 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Press trim strip -1- evenly -arrow- into window channel -2- by hand. – Then press window channel -2- fully into mounting of trim strip with roller -T 10314- .

  • Page 312: Assembly Overview - Window Regulator Motor

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - window regulator motor Note The right side is shown. The left side is similar. 1 - Connector 2 - Bolt ❑ Qty. 3 ❑...
  • Page 313 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Secure door window against sliding down with adhesive tape. – Remove the three bolts -2-. – Disconnect connector -1-. – Remove window regulator motor with control unit -3- from mounting plate.
  • Page 314 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Further installation is performed in reverse order of removal. Rep. Gr.64 - Glazing...

  • Page 315: Assembly Overview - Window Regulator

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - window regulator Note The right side is shown. The left side is similar. 1 - Window regulator ❑ Removing and installing ⇒ page 305 2 - Bolt ❑...
  • Page 316 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 3.10.1 Removing – Remove door outer panel ⇒ page 112 – Removing door window ⇒ page 294 – Remove bolts -2- from mounting plate -3-.

  • Page 317: Rear Door Window (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear door window (Variant) Tools Special tools and workshop equipment required ♦ Roller -T10314- ♦ Torque wrench -V.A.G 1783- 4. Rear door window (Variant)

  • Page 318: Assembly Overview - Rear Door Window

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear door window Note The right side is shown. The left side is similar. 1 - Door window ❑ Removing and installing ⇒...
  • Page 319 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.3.1 Removing – Remove rear door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim . – Lower door window completely. – Pull window channel -3- out of mounting.

  • Page 320: Removing And Installing Window Slot Outer Seal

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Pull door window upwards -arrow- out of window slot. 4.3.2 Installing Note When installing door window, always renew spreader plug and ♦ spreader pin.

  • Page 321: Assembly Overview - Door With Fixed Window With Window Channel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Lever spreader clip -4- out of clip -3- using a small screwdriver. – Pull the four clips -3- out of the window slot seal -2-.

  • Page 322: Removing And Installing Door With Fixed Window With Window Channel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing door with fixed window with window channel Note The removal and installation sequence is only for the right door fixed window with window channel. The removal and installation of the left door fixed window with window channel is similar.
  • Page 323 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Push window channel -2- in top front area slightly to side. – Remove spreader rivet -5- for window channel trim strip -1-. All vehicles –...
  • Page 324 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolt -4-. – Pull middle frame -3- out of clips -2- and window channel -1-. – Take fixed door window -5- out of window channel -1-.
  • Page 325 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.6.2 Installing Spray window channel with soapy water when installing. Further installation is performed in reverse order of removal. Use a new clip when installing middle frame.

  • Page 326: Removing And Installing Window Channel Trim Strip

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing window chan‐ nel trim strip 4.7.1 Removing – Push window channel -2- in top front area slightly to side. – Remove spreader rivet -5- for window channel trim strip -1-.

  • Page 327: Assembly Overview - Window Regulator Motor

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - window regulator motor Note The right side is shown. The left side is similar. 1 - Connector 2 - Bolt ❑ Qty. 3 ❑...
  • Page 328 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Secure door window against sliding down with adhesive tape. – Pull connector -1- in direction of -arrow- off window regulator motor with control unit -3-.
  • Page 329 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Further installation is performed in reverse order of removal. 4. Rear door window (Variant)

  • Page 330: Exterior Equipment

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 66 – Exterior equipment Wheel housing liner Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. Gr.66 - Exterior equipment...

  • Page 331: Assembly Overview - Front Wheel Housing Liner

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - front wheel housing liner Note Only the left side is shown. The right side is similar. ♦ The removal and installation procedures may have to be modified slightly depending on variations in equip‐...
  • Page 332 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 1.3.1 Removing Wheel housing liner rear part – Remove wheel ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques for wheel bolts .

  • Page 333: Assembly Overview - Rear Wheel Housing Liner

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - rear wheel housing liner Note Only the left side is shown. The right side is similar. 1 - Wheel housing liner ❑ Material: PP/EPDM 2 - Bolt ❑...

  • Page 334: Installing Protective Cover For Wheel Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove bolts -2- (Qty 9). – Pull off wheel housing liner -1-. 1.5.2 Installing Install in reverse order of removal. Installing protective cover for wheel housing 1.6.1...
  • Page 335 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Stick protective cover -2- on approx. 28.7 mm from -A-, where the highest point of the protective cover -2- and the upper edge of the bumper cover -3- are used as reference points.

  • Page 336: Exterior Mirror

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Exterior mirror Tools Special tools and workshop equipment required ♦ Removal lever -80-200- ♦ Torque wrench -V.A.G 1783- Rep. Gr.66 - Exterior equipment...

  • Page 337: Assembly Overview - Exterior Mirror

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - exterior mirror Note Only the left side is shown. The right side is similar. 1 - Mirror housing ❑ Material: ABS. ❑ Removing and installing ⇒...

  • Page 338: Removing And Installing Mirror Glass

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing mirror glass Note The removal and installation sequence is only for the left mirror glass. The removal and installation of the right mirror glass is similar.

  • Page 339: Removing And Installing Trim

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.4.1 Removing – Remove mirror glass ⇒ page 328 – For ease of assembly, fold exterior mirror forwards. – Using a screwdriver underneath the locking hooks -2- press mirror housing out of fastening.

  • Page 340: Removing And Installing Side Turn Signal Repeaters

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing side turn signal repeaters Note The removal and installation sequence is only for the left side ♦ mounted turn signal. The removal and installation of the right side turn signal repeater is similar.

  • Page 341: Removing And Installing Adjustment Unit With Motor For Exterior Mirror

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Remove assembly part with turn signal repeater ⇒ page 330 – Remove bolt -1-. – Swing entry light -2- out downwards and pull bulb out of entry light housing.
  • Page 342 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 2.9.1 Removing – Removing front door trim on driver's side ⇒ General body re‐ pairs, interior; Rep. Gr. 70 ; Door trim . – Release cable retainer -2- and detach connector -1- for exte‐...

  • Page 343: Roof Railing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Roof railing Tools Special tools and workshop equipment required ♦ Torque wrench 5…50 Nm -V.A.G 1331- ♦ Plastic wedge -T10039/1- 3. Roof railing...

  • Page 344: Assembly Overview - Roof Railing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Assembly overview - roof railing 1 - Roof railing ❑ Removing and installing ⇒ page 334 2 - Bolt ❑ Qty. 3 on each side ❑...
  • Page 345 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Lever front and rear covers of roof railing -1- in direction of -arrow A- and press them in direction of -arrow B-. – Pull out cover for roof railing -1-.

  • Page 346: Radiator Grille

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Radiator grille Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- Rep. Gr.66 - Exterior equipment...

  • Page 347: Radiator Grille

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Radiator grille 4.2.1 Assembly overview - radiator grille 1 - Radiator grille ❑ Removing ⇒ page 337 ❑ Installing ⇒ page 338 2 - Bolt ❑...
  • Page 348 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Tilt radiator grille -1- forwards slightly and pull it upwards out of bumper cover. 4.2.3 Installing – Insert radiator grille -1- into bumper cover mounting from above and tilted forwards slightly.
  • Page 349 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Install bolts -2- (2 Nm). 4. Radiator grille...

  • Page 350: Radiator Grille, Cup Edition

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Radiator grille, Cup Edition 4.3.1 Assembly overview - radiator grille 1 - Radiator grille ❑ Removing ⇒ page 341 ❑ Installing ⇒ page 342 2 - Bolt ❑...
  • Page 351 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.3.2 Removing – Remove bolts -2-. – Release clips -arrows- from lock carrier using a small screw‐ driver. – Tilt radiator grille -1- backwards slightly and pull locking hooks -3- upwards out of front bumper cover.
  • Page 352 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.3.3 Installing – With radiator grille -1- tilted forward slightly place locking hooks -3- in front bumper cover. – Tilt radiator grille -1- towards lock carrier and locate clips -arrows- in lock carrier.
  • Page 353 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 4.3.4 Removing and installing emblem Removing – Release locking hooks -arrows- on rear of emblem -2- with radiator grille removed -1-. – Turn emblem -2- in -direction of arrow- slightly and pull em‐...

  • Page 354: Mouldings And Trims

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Mouldings and trims Tools Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783- ♦ Double cartridge gun -VAS 5237- ♦ Hot air blower -V.A.G 1416- ♦...

  • Page 355: Removing And Installing Side Panel Trim Strips On Gli Vehicles

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Removing and installing side panel trim strips on GLI vehicles 5.2.1 Removing – Remove bolts -1- (Torx T25) from body. – Remove side panel trim strip -2- in direction of -arrow-.

  • Page 356: Side Member Extension, Jetta Cup Edition

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Starting at rear of retainer, position side panel trim strip -2- over retainer -4-. – Secure front of side panel trim strip -2- using a bolt -1-. Speci‐...
  • Page 357 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 5.3.1 Assembly overview 1 - Side member extension ❑ Removing ⇒ page 348 ❑ Installing ⇒ page 349 2 - PUR adhesive sealant ❑ Lower adhesive surface ❑...
  • Page 358 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 5.3.2 Removing Note The side member extension cannot be removed without being damaged. WARNING Clean all surrounding parts before beginning work and mask them with tape.
  • Page 359 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Lift a corner of side member extension -1- using wedge -3409- . – Firmly holding corner, forcefully pull side member extension -1- from side panel.
  • Page 360 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 – Install side member extension -1- on side member, start at rear wheel housing and use assistance of a second mechanic. – Then tighten bolt -2-.

  • Page 361: Special Add-On Parts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Special add-on parts Safety requirements Caution When removing special add-on parts, use suitable gloves and protective eyewear. Special add-on parts must cure at least 3 hours after being bonded before work on the vehicle is continued.

  • Page 362: Special Add-On Parts, Jetta Cup Edition

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Heat 1-K glass adhesive according to manufacturer's instructions, using cartridge heater -V.A.G 1939A- . Special add-on parts, Jetta Cup Edition 1 - Radiator grille ❑ Removing ⇒...

  • Page 363: Preparing New Add-On Part For Bonding

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 WARNING Activator must not have contact with paint or the paintwork will be damaged. Note If the body kit part has been repaired or partially renewed, the area concerned must be cleaned and primed again after painting.

  • Page 364: Minimum Curing Period

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 ♦ Use adhesive tape to secure add-on parts in position during minimum curing time. Minimum curing period The minimum curing period for newly bonded attaching parts is 3 hours.

  • Page 365: Protective Backing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Protective backing Scuff protection film 7.1.1 Tools Special tools and workshop equipment required ♦ Hot air blower -V.A.G 1416- 7.1.2 Fitting notes Note Before removal, heat the scuff protection film with a hot air ♦...
  • Page 366 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 7.1.3 Renewing scuff protection film Note Renewing scuff protection films is described only for the left side. The right side is similar. Removing – Remove inner seal for front door in area of side member ⇒...

  • Page 367: Lettering

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Lettering Tools Special tools and workshop equipment required ♦ Hot air blower -V.A.G 1416- Installation instructions for lettering and emblems Note Before removal, heat lettering or emblem with a hot air blower ♦...

  • Page 368: Rear Lettering Dimensions (Saloon)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear lettering dimensions (saloon) 1 - Dimension -a- = 25 mm ❑ From outer edge of rear lid to lettering 2 - Dimension -b- = 15 mm ❑...

  • Page 369: Rear Lettering Dimensions (Variant)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Rear lettering dimensions (Variant) 8.4.1 Lettering (Golf Variant) 1 - Dimension -a- = 5 mm ❑ Lower edge of lettering to height of lower edge of rear light -1- ❑...
  • Page 370 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 8.4.2 Lettering (Jetta Variant) 1 - Dimension -a- = 25 mm ❑ Transfer -dimension a- from outer edge of rear lid to lettering. ❑ Lower edge of lettering...

  • Page 371: Side Lettering Dimensions - Individual

    Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 Side lettering dimensions - Individual 8.5.1 Dimensions for emblem on left wing 1 - Dimension -a- = 551 mm ❑ Transfer -dimension a - from lower edge of wing to wing.
  • Page 372 Golf Variant 2007 ➤ , Jetta 2005 ➤ General body repairs, exterior - Edition 10.2009 8.5.2 Dimensions for emblem on right wing 1 - Dimension -a- = 550 mm ❑ Transfer -dimension a - from lower edge of wing to wing.

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Golf variant 2007

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