D3E801425F8-Body Repair

Service
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Body Repair
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Golf 1999 ➤
GTI/Jetta 1999 ➤
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Jetta Wagon 1999 ➤
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Edition 07.2007
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Service Department. Technical Information

Service
Repair Group overview for Body Repairs
Repair Group
00 - General, Technical Data
50 - Body - Front
51 - Body - Center, Chassis, Roof
53 - Body - Rear AG. Volkswagen AG d
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2008 Volkswagen AG, Wolfsburg D3E801425F8

Golf 1999 ➤ , GTI/Jetta 1999 ➤ , Jetta Wagon 1999 ➤
Body Repair - Edition 07.2007
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AG. Volkswagen AG d
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Contents
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00 - General,
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Technical Data . . . . . . . . .nte.e .o . . . . . . ........................... 1
aut ra
ss 1 General Information . . . . . . . . . . . . . . . .c . . . . . . ................................ 1
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1.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 Body Foam Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.2 Reinforced Body Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.3 Laser Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
hole
spec
2.4 Galvanized Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Body Panel Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Body Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4.1 Straightening Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
50 - Body - Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
nform
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1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1.1 Engine Mount Bracket, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1.2 Intermediate Piece, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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1.3 Fender Connecting Plate, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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1.4 Longitudinal Member, Upper Wheel Housing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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1.5 Front Wheel Housing, Partial Section, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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1.6 Front Inner Fender, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.7 Front Longitudinal Member, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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AG.
72
1.9 Longitudinal Member, Front Section, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
51 - Body - Center, Chassis, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.1 Roof Rail Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Roof, Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Roof, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3 Roof, Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Roof Front Crossmember, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.5 Roof Reinforcement, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.6 Rear Roof Cross Member, Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.7 Rear Cross Member, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.8 Rear Roof Crossmember, Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.9 A-Pillar, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.10 Inner A-Pillar, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.11 B-Pillar, Replacing, 4 Door and Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.12 Inner B-Pillar, Replacing, 2 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.13 Inner B-Pillar, Replacing, 4 Door and Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.14 Outer Side Member, Replacing, 2 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.15 Outer Side Member, Replacing, 4 Door and Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.16 Side Member Reinforcement, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.17 Floor Plate, Partial Section, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
53 - Body - Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1.1 Rear Cross Panel, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.2 Rear Cross Panel, Exterior, Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Contents i
1.3 Rear Cross Panel, Complete, Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1.4 Tail Lamp Cluster Mount, Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.5 Rear Center Cross Panel Carrier, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.6 Rear Cross Panel, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.7 End Cross Panel, Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.8 Outer Wheel Housing, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.9 C-Pillar Reinforcement, Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.10 Rear Longitudinal Member, Partial Section Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . 143
1.11 Rear Longitudinal Member, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.12 Longitudinal Member, Partial Section Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.13 Quarter Panel, Partial Section Replacing, 2 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.14 Quarter Panel, Partial Section, Golf 4 Door, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.15 Quarter Panel, Partial Section Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.16 Side Panel, Partial Section Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.17 Quarter Panel, Partial Section, Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.18 Wheel Housing Connection Panel, Partial Section Replacing, Jetta . . . . . . . . . . . . . . . . . . 163
1.19 Connecting Panel, Replacing, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.20 Outer Rear Wheel Housing, Partial Section Replacing, Jetta Wagon . . . . . . . . . . . . . . . . 166
1.21 Spare Wheel Well, Replacing, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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1.22 Spare Wheel Well, Partial Section Replacing, Golf . . . . . s.w.a.ge.n.A.G.. . . . . . g. e.n.A.G.d.oe.s. . . . . . 170
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1.23 Spare Wheel Well, Replacing, Jetta . . . . . . . . . . . .d.by. V. . . . . . . . . . . . . . . . . . . . . . . . t.g.ua.r .
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ii Contents
00 – General, Technical Data

1 General Information
⇒ “1.1 Technical Data”, page 1
1.1 Technical Data

VIN
The vehicle identification number (chassis number) is stamped
on the right side of the engine compartment rear bulk head. View
it through a window in the plenum chamber cover.
Vehicle Information Label
Information label is located on the front longitudinal member

-arrow-, above the horns.
Note
Lift the vehicle and use a mirror -1- to see the label -arrow-.
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1. General Information
Vehicle information label contains:

a .- PKN (7 Digits), example: 1719016
b .- Color, example: B7B7
c .- Commercial code: 1C13L4
d .- Destination: X9A
Vehicle Data Label
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Vehicle Data Label, Jetta from 04.00

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Vehicle data label is located next to spare tire wheel well, near
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rear left wheelhouse.

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2 Rep. Gr.00 - General, Technical Data

2 Description and Operation

⇒ “2.1 Body Foam Insulation”, page 3
⇒ “2.2 Reinforced Body Sheet Metal”, page 3
⇒ “2.3 Laser Welding”, page 4
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⇒ “2.4 Galvanized Body Panels”, page 5 Volksw
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Foam treating reduces noise transfer to the interior.
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Foam insulation is a pre-formed synthetic material.
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The parts catalog shows insulation on illustration 863-20.
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The pre-formed foam parts are installed during body assembly,
they expand during drying time in the paint shop oven at approx.
180° C (388° F) after priming.
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As these temperatures cannot be achieved under normal work‐
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shop conditions, proceed as follows:

Requirements
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Before continuing with this procedure, ensure that the part for re‐
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– Remove excess foam material.
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– Repaint, apply two coats (wet on wet) glass/paint primer D009

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200 02 if necessary, flash-off time - approx.10 min.

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– Install insulation on vehicle.

– Attach new part (e.g. A-pillar) and locate new part by pressing
gently in area of insulation and weld in place.
– Do not SG weld 15 mm (0.59 in.) either side of insulation.
Re-under coat repaired area after painting vehicle, as required.
2.2 Reinforced Body Sheet Metal

The following areas use reinforced body sheet metal:
2. Description and Operation 3

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♦ Various front frame parts (highlighted area)
♦ Plenum panel (shaded area)
♦ B-pillar (shaded area)
♦ Rear reinforcements (shaded area)
2.3 Laser Welding

The area below the drip rail is laser welded.
With laser welding a light beam of high energy is guided over the
weld via optical lenses or fibre optics.
During the welding process the upper panel is melted onto the
partially molten lower panel creating a weld joint without the need
of additional material.
During collision repair the laser weld seam is replaced by an SG-
plug weld seam.

2.4 Galvanized Body Panels

The 1999 Golf/Jetta consist completely of body panels galvanized
on both sides!
Before performing body repairs observe the following information,
refer to ⇒ General Information; Body Repairs, Body Collision Re‐
pair
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2. Description and Operation 5

3 Specifications
⇒ “3.1 Body Panel Gaps”, page 6
⇒ “3.2 Body Dimensions”, page 17
3.1 Body Panel Gaps

⇒ “3.1.1 Body, Front, Golf”, page 6
⇒ “3.1.2 Body, Rear, Golf”, page 7
⇒ “3.1.3 Body, Front, Golf from 2008”, page 9
⇒ “3.1.4 Rear Side, from 2008”, page 11
⇒ “3.1.5 Body, Rear, Jetta”, page 13
⇒ “3.1.6 Body, Rear, Jetta Wagon”, page 14
3.1.1 Body, Front, Golf

Special tools and workshop equipment required
♦ Adjustment gauge -3371-
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D - 2.0 mm (0.078 in.)

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F - 3.0 mm (0.118 in.)

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G - 3.5 mm (0.137 in.)
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H - 4.0 mm (0.157 in.)

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K - 5.0 mm (0.196 in.)

L - 5.5 mm (0.216 in.)
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3.1.2 Body, Rear, Golf

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3. Specifications 7
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D - 2.0 mm (0.078 in.)

G - 3.5 mm (0.137 in.)
H - 4.0 mm (0.157 in.)
K - 5.0 mm (0.196 in.)
M - 6.0 mm (0.236 in.)

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♦ The clearances are always indicated in mm.

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♦ The clearances are always indicated in mm.

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F - 3.0 mm (0.118 in.)
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H - 4.0 mm (0.157 in.)

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3.1.6 Body, Rear, Jetta Wagon

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3.2 Body Dimensions

⇒ “3.2.1 Body, Front”, page 17
⇒ “3.2.2 Body, Center”, page 21
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Note
Front and middle areas of body are the same for Jetta and Golf.
Dimension between front strut towers

Dimension between front longitudinal members
WARNING
Dimensions only given for checking purposes. The straighten‐

ing fixture dictates final figures.
Dimension between hood hinge mounts (cover hinge attachment)
AG. Volkswagen AG d
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Dimension between wheel house points
WARNING

Diagonal dimension between hood hinge mount to wheel house

front upper corner

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Dimension from cowl to roof flange
3.2.2 Body, Center
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Front door opening (2 door)

Front door opening (4 door)
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Front door opening height, for two and four door vehicles is the
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Rear door opening

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Dimension between A-pillars
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Body, rear (Golf), refer to ⇒ “3.2.3 Body, Rear, Golf”, page 28
3.2.3 Body, Rear, Golf
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Dimension between rear wheel house
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Trunk width at opening

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Floor, front
WARNING

Floor, center

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3. Specifications
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4 Special Tools
⇒ “4.1 Straightening Fixture”, page 40
4.1 Straightening Fixture

⇒ “4.1.1 Straightening Fixture”, page 40
⇒ “4.1.2 Front Alignment Brackets Overview, Right”, page 43
⇒ “4.1.3 Front Alignment Brackets Overview”, page 45
⇒ “4.1.4 Alignment Brackets in Door Center Overview”,
page 49
⇒ “4.1.5 Center Alignment Brackets Overview”, page 51
⇒ “4.1.6 Rear Alignment Brackets Overview”, page 53
4.1.1 Straightening Fixture
Note
RW = Angle
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Note
♦ Item numbers in illustration are identical with end numbers on

straightening bracket inserts
♦ For angle required basic set size is specified
♦ -VAS 5090- or
♦ -VAS 5020- plus -VAS 5020/2- (for Golf/Jetta from MY 1999)
♦ The following instructions show right side of vehicle
6 - MZ 142
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4. Special Tools 41
8 - MZ 260
10 - MZ 200
14 - MZ 601
16 - Locating (centering) pin, left and right AG. Volkswagen AG d
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42 - MZ 200 and TV 400 byV
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44 - On RW -42- ut
hor eo
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18 - MZ 140 s
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20 - Without locating bracket MZ

22 - No locating bracket -20-
26 - MZ 140
28 - MZ 080
30 - MZ 080
31 - Locating bracket RW -30-
en AG. V
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32 - MZ 602 y Vol gu
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34 - MZ 200 uthor eo
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4.1.2 Front Alignment Brackets Overview, Right
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Cop py
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Prote AG.
42 - RW Front longitudinal member

44 - RW Front longitudinal member/wheel house upper corner
42 - RW for Front longitudinal member
4. Special Tools 43
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44 - RW for wheel house point

o
n
c
i
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46 - Locating bracket for -42- and -44-
thi
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♦ This combination of angles is used to position wheelhouse
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point. cop Vo
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♦ Bracket -46- is adjusted with thumb screw and bolts - -T044-
AG.
to longitudinal member.

4.1.3 Front Alignment Brackets Overview
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4. Special Tools 45
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8 - RW for engine mount carrier
t to the co
9 - RW for transmission mount carrier
rrectness of i
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4. Special Tools 47
AG. Volkswagen AG d
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pt
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6 - Angle for front longmember

10 - Carrier assembly mount
14 - Strut mounting plate
16 - Strut mount
4.1.4 Alignment Brackets in Door Center Overview
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c
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do
priv
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Note
Co
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The door opening square (or angle) is checked with this tool. Also, cop Vo
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the hinges to striker (latch) are checked for alignment to A and B- cted agen
Prote AG.
pillars
4. Special Tools 49
AG. Volkswagen AG d
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The door opening square is checked with this tool. Also, the hing‐
AG.
es to striker (latch) are checked for alignment to A, B and C-pillars

AG. Volkswagen AG d
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Golf thor1999 ➤ , GTI/Jetta 1999 ➤ , Jetta Wagon 1999
eo ➤
u ra
ss a Body Repair - Edition 07.2007
c
ce
e
nl
pt
du
4.1.5 Center Alignment Brackets Overview
an
itte
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t to the co
rrectness of i
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mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
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4. Special Tools 51
AG. Volkswagen AG d
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pe
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18 - Locating bracket in longitudinal member
ot
wit
, is n
20 - Base for 22
h re
hole
spec
22 - Front production mount, left and right identical
es, in part or in w
t to the co
Can be pushed up, use packing up to 4mm (0.15 in.) when meas‐
uring if necessary.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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Cop py
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Prote AG.

26 - Dimensional check, floor pan locating hole

28 - Locating hole in longitudinal member
4.1.6 Rear Alignment Brackets Overview
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com
tion in
r
te o
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Cop py
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4. Special Tools 53
AG. Volkswagen AG d
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du
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30 - Rear axle mount
ility
ot p
wit
♦ Stake it after positioning

, is n
h re
hole
31 - Spacer, left and right

spec
es, in part or in w
♦ Use only with rear axle removed

t to the co
32 - Suspension strut mount

rrectness of i
34 - To locate hole in longitudinal member

l purpos
Jetta wagon
nf
ercia
orm
Note
m
atio
om
n in
c
♦ Body options:
or
thi
te
sd
a
♦ -VAS 5020/3- , additional Jetta/Jetta Wagon

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96 - MZ 200 and TV 400
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Overview of alignment bracket positions, rear
4. Special Tools 55
AG. Volkswagen AG d
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ion
c
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Overview of alignment bracket positions, rear Prote
cted AG.
agen

96 - Mount for hole in long‐

member, rear
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es, in part or in w
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at
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ion
c
in t
or
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do
priv
cum
for
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Cop py
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Prote AG.
4. Special Tools 57
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Golf 1999 ➤ , GTI/Jetta
tho 1999 ➤ , Jetta Wagon 1999 ➤ tee
or
u
Body Repair - sEdition
s a
07.2007 ac
ce
e
nl
pt
du
an
itte
50 – Body - Front
y li
erm
ab
ility
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1 Removal and Installation
h re
hole
spec
es, in part or in w
⇒ “1.1 Engine Mount Bracket, Replacing”, page 58
t to the co
⇒ “1.2 Intermediate Piece, Replacing”, page 60
⇒ “1.3 Fender Connecting Plate, Replacing”, page 62
rrectness of i
⇒ “1.3 Fender Connecting Plate, Replacing”, page 62
l purpos
⇒ “1.5 Front Wheel Housing, Partial Section, Replacing”,

page 66
nform
ercia
⇒ “1.6 Front Inner Fender, Replacing”, page 68

m
at
om
io
⇒ “1.7 Front Longitudinal Member, Replacing”, page 70
n
c
in t
or
his
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⇒ “1.8 Front Longitudinal Member, Partial Section, Replacing”,

at
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page 72
p
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⇒ “1.9 Longitudinal Member, Front Section, Replacing”,

n
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page 74 C py
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1.1 Engine Mount Bracket, Replacing cop Vo
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Right Engine Mount Bracket
58 Rep. Gr.50 - Body - Front

AG. Volkswagen AG d
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Cutting Location pt
an
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– Separate engine mount bracket.
erm
ab
ility
ot p
– Separate original joint.

wit
is n
h re
– Remove front section.

ole,
spec
– Drill out welding points -a-, 7 mm dia. (0.275 in.).

t to the co
– Remove excess material

Replacement Part
rrectne
♦ Engine mount bracket

ss o
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Cop py
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Prote AG.
1. Removal and Installation 59

Preparing New Part

– Drill 7 mm (0.275 in.) dia. holes for SG-plug weld seam.
Welding in Place
– Install new part using straightening bracket.
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– Weld mount bracket in place, SG-plug weld seam.
pe
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– Weld in weld points -a- from outside, SG-plug weld seam.
h re
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es, in part or in w
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nform
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ti
1.2 Intermediate Piece, Replacing
on in
r
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Cutting Location
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Prote AG.
Offset parting cut 50 mm (1.96 in.) to fender connecting plate and
intermediate piece.
Partial Repair:
If extent of damage permits, parting cuts can be vertical.
Butt weld parting cut, SG-continuous weld seam.

Body Repair - Edition 07.2007 en AG. V
olkswagen AG
ag does
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– Remove excess material. ed
b ara
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oris eo
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Replacement Part au
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♦ Connecting plate
ce
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pt
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Welding in Place
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– Secure new part and check gaps/mating lines with attaching
ility
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rrectness of i
– Spot weld intermediate piece, RP-spot weld seam.
l purpos
– Weld in fender connecting plate. Refer to

⇒ “1.3 Fender Connecting Plate, Replacing”, page 62 .
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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Cop py
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1.3 Fender Connecting Plate, Replacing
co lksw
by
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Cutting Location

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es, in part or in w
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mercia
a
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tion in
r
te o
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Cop py
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cted agen
Prote AG.
– Cut out connecting plate.

Note
Offset parting cut 50 mm (1.96 in.) to fender connecting plate and

wheel house upper longitudinal member.
Partial Repair:
A partial repair is possible using parting cut -1- shown.

AG. Volkswagen AG d
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Golf 1999 ➤ , GTI/Jetta 1999 ➤uth, Jetta Wagon 1999 ➤
o eo
ra
a
Body Repair - Edition 07.2007ss c
ce
le
un
pt
– Remove excess material.
an
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Replacement Part
pe
ility
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♦ Connecting plate
, is n
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hole
Preparing New Part
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Transfer separating lines to new part and cut-out.

m
a
Welding in Place
com
tion in
r

te o
thi
parts.
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rig ht
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by lksw
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Prote AG.
– Weld new part in place, RP-spot weld seam.

– Butt weld parting cut, SG-continuous weld seam.
– Weld in longitudinal member for wheel house. Refer to
⇒ “1.4 Longitudinal Member, Upper Wheel Housing, Replac‐
ing”, page 64 .
1.4 Longitudinal Member, Upper Wheel

Housing, Replacing
Cutting Location

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l purpos
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c
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– Cut out upper wheel house longitudinal member according to p by
co Vo
by lksw
degree of damage. Prote
cted AG.
agen
Note
If damage is beyond prescribed separating lines -1-, inner A pillar

must be replaced as well.

Partial Repair:
A partial repair, depending on damage, is possible using parting
cuts -a- shown.

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Golf 1999 ➤ , GTI/Jetta 1999 ➤ , Jetta Wagon 1999 ➤ horis tee
t or
Body Repair - Edition 07.2007 au ac
ss
ce
le
un
pt
an
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Replacement Part
rm
ab
pe
ility
♦ Upper wheel house longitudinal member
ot
wit
, is n
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Preparing New Part
hole
spec
es, in part or in w
– Transfer separating lines to new part and cut.
t to the co
Welding in Place
– Install and secure new part in position.
rrectness of i
l purpos
– Spot weld upper wheel house longitudinal member, RP-spot
nform
ercia
weld seam.
m
a
com
ti
on in
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te o
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Cop py
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co lksw
by
cted agen
Prote AG.
1.5 Front Wheel Housing, Partial Section,

Replacing
• longitudinal member for upper wheel house already cut out.

AG. Volkswagen AG d
agen oes
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t to the co
rrectne
• Fender connecting plate already cut out.

• Intermediate piece already cut out.
ss o
Cutting Location
cial p
f inform

mer
atio
m

o
n
c
i
or
n thi
Replacement Part
te
sd
iva
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pr
♦ Inner front wheel house

um
r
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Golf 1999 ➤ , GTI/Jetta 1999 ➤ag,enJetta
AG. VWagon
olkswagen1999
AG do ➤
sw es n
y Volk ot g
u b ara
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ris
Preparing New Part au
tho e or
ac
ss
– Drill 7mm (0.27 in.) holes for SG-plug weld seam
ce
le
un
pt
an
d
Welding in Place itte
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erm
ab
ility
ot p
parts.
wit
is n
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ole,
spec
t to the co
rrectness
– Spot weld wheel house, RP-spot weld seam.
o
cial p
f inform
– Apply overlapping weld to both sides of lower parting cut, SG-
mer
continuous weld seam (staggered).
atio
om
n
c
– Weld intermediate piece in place. Refer to
i
or
n thi
⇒ “1.2 Intermediate Piece, Replacing”, page 60
te
sd
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o
pr
cum
r
fo
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.6 Front Inner Fender, Replacing

♦ Front fender removed

AG. Volkswagen AG d
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rise nte
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Fender connecting piece removed

♦ Intermediate piece removed
Cutting Location
– Remove inner fender.
Replacement Part
♦ Wheel house

Preparing New Part

– Transfer separating lines to new part plus 10 mm (0.393 in.)
for overlap and cut-out highlighted area.
– Offset body side.
Welding in Place
– Install new part and secure on fixture.
– Weld separating cut, SG-continuous weld seam.

– Spot weld remainder of joint, RP-spot weld seam.
– Weld connecting piece n AG. Volkswagen AG do
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ility
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hole
1.7 Front Longitudinal Member, Replacing
spec
es, in part or in w
t to the co
Cutting Location
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
– Remove longitudinal member

t to the co
– Separate original joint

rrectness of i
Replacement Part
l purpos
♦ longitudinal member
nform
ercia
Preparing New Part

m
at
– Transfer separating lines to new part and remove highlighted

om
ion
area.
c
in t
or
his
e
– Drill 7 mm dia. (0.27 in.) holes for SG-plug weld seam.

at
do
priv
cum
or
Welding in Place
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Install new part on straightening fixture.

lkswage es n
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– Weld longitudinal member, SG-plug weld
ss
a seam. ac
ce
e
– Front longitudinal member, Welding in Place, refer to

nl
pt
du
an
itte
y li
page 72
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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1.8 Front Longitudinal Member, Partial Sec‐

tion, Replacing
nf
ercia
orm
Cutting Location
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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e
nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Make parting cuts according to degree of damage.
l purpos
nform
ercia
Note
m
at
om
Parting cut must be straight.

ion
c
in t
or
his
e
Replacement Part
at
do
priv
cum
or
♦ Longitudinal member
f
en
ng
t.
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Preparing New Part . Cop py
rig
ht ht
rig
– Transfer separating lines to new part and remove highlighted py by
co Vo
area.
by lksw
cted agen
Prote AG.
Welding in Place
– Position longitudinal member on fixture.

– Depending on degree damage, butt weld parting cut, SG-con‐

tinuous weld seam.
– Front longitudinal member, welding in place, refer to
page 72 .
Note
Weld points must run parallel with one another if repairs to longi‐
tudinal member and covering plate are performed as individual
parts. Dimension must be adhered to.
AG. Volkswagen AG d
agen oes
olksw not
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ara
1.9 Longitudinal Member, Front Section, ed
ris nte
ho eo
ut
Replacing ss a ra
c
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un
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itte
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Note
rm
ab
pe
ility
ot
Remove towing eye first to replace right longitudinal member front
wit
, is n
section.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

agen
AG. Volkswagen AG d
oes Body Repair - Edition 07.2007
olksw not
y V gu
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Cutting Location
– Make parting cut in front of weld seam.

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
– Remove excess material opy
rig by
Vo
ht
by c lksw
Replacement Parts Prote
cted AG.
agen
♦ Towing eye (right side only)

♦ Impact damper mount
Welding in Place
– Install new part and secure on fixture.
– Weld in impact damper mount, SG-continuous weld seam.

– Weld in towing eye, SG-continuous weld seam.

– Dimension --a-- = 70 mm (2.75 in.)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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un
pt
an
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
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Vo
o
by c lksw
cted agen
Prote AG.

51 – Body - Center, Chassis, Roof

1 Specifications
olkswagen AG
en AG. V
⇒ “1.1 Roof Rail Dimensions”,
olks
wag page 78 does
not
yV gu
db ara
1.1 Roof
tho
ris Rail Dimensions
e nte
eo
au ra
c
ss
ce
le
a - 34 mm
un
pt
an
d
itte
y li
b - 153 mm
rm
ab
pe
ility
c - 1155 mm
ot
wit
, is n
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d - 29 mm
hole
spec
e - 523 mm
es, in part or in w
t to the co
f - 26 mm
g - 146 mm
rrectness of i
Note
l purpos
nform
mercia
a
com
tion in
r
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Cop py
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by c lksw
cted agen
Prote AG.
78 Rep. Gr.51 - Body - Center, Chassis, Roof

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nl
pt
du
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
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l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.

lkswage es n
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2 Removal and Installation ir se
d byV ua
ran
tee
tho
or
⇒ “2.1 Roof, Replacing, Golf”, page 80 ss
au ac
ce
e
⇒ “2.2 Roof, Replacing, Jetta”, page 83
nl
pt
du
an
itte
y li
⇒ “2.3 Roof, Replacing, Jetta Wagon”, page 85
erm
ab
ility
ot p
⇒ “2.4 Roof Front Crossmember, Replacing”, page 90
wit
, is n
h re
⇒ “2.5 Roof Reinforcement, Replacing”, page 92
hole
spec
⇒ “2.6 Rear Roof Cross Member, Replacing, Golf”, page 93
es, in part or in w
t to the co
⇒ “2.7 Rear Cross Member, Replacing, Jetta”, page 95
⇒ “2.8 Rear Roof Crossmember, Replacing, Jetta Wagon”, page
rrectness of i
96
⇒ “2.9 A-Pillar, Replacing”, page 98 l purpos
⇒ “2.10 Inner A-Pillar, Replacing”, page 101
nform
ercia
⇒ “2.11 B-Pillar, Replacing, 4 Door and Jetta”, page 104

m
at
om
i
⇒ “2.12 Inner B-Pillar, Replacing, 2 Door”, page 106
on
c
in t
or
⇒ “2.13 Inner B-Pillar, Replacing, 4 Door and Jetta”, page 108
his
ate
do
priv
c
⇒ “2.14 Outer Side Member, Replacing, 2 Door”, page 112
um
for
en
ng
t.
⇒ “2.15 Outer Side Member, Replacing, 4 Door and Jetta”,
yi Co
op
page 115
C py
t. rig
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⇒ “2.16 Side Member Reinforcement, Replacing”, page 116 cop Vo
by lksw
cted agen
Prote AG.
⇒ “2.17 Floor Plate, Partial Section, Replacing”, page 119
2.1 Roof, Replacing, Golf

1 - Bonded area

Cutting Location
– Rough cut roof out.
Note
♦ Special hose with reduced nozzle diameter is required for

shielding gas welding unit to arepair
gen AGroof.
. Volkswagen AG
do
ksw es n
Vol ot g
♦ VAS5023 Hoses ed by ua
ran
ris tee
♦ VAS5023/2 - Nozzle
au
tho set or
ac
ss
ce
e
– Remove sealant from sealing channel.

nl
pt
du
an
itte
y li
– Grind laser weld seam down, bend excess material up with a
erm
ab
chisel and remove.
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
Only grind laser weld seam down. Do not grind through roof. Roof
frame must be replaced as well if it is damaged.
rrectness of i
l purpos
– Remove adhesive residue completely and grind adhesive sur‐

face back to bare metal.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
– Clean spot weld flange, from inside, to bright surface with a
t. rig
gh ht
yri
die grinder and appropriate tool.
p by
o Vo
by c lksw
cted agen
Replacement Part
Prote AG.
♦ Roof
♦ Butyl adhesive sealing cord AKL 450 005 05
♦ Adhesive: DA 001 730 A1
Preparing New Part
– Slot enlargement must be cut in horizontal roof flange with

bench grinder or angled grinder for later SG-plug weld seam.
– Spacing approx. 45 - 50 mm (1.77 - 1.97 in.).
Welding in Place
– Before welding in roof, apply Butyl adhesive sealing cord to
roof reinforcement.

– Apply adhesive before Welding in Place.
WARNING
New part must be installed within 30 minutes, otherwise adhe‐

sive properties will be impaired.
WARNING
Check fit with windshield and rear window. It is essential that

dimension -a- = 13.2 ± 0.6 mm (0.519 ± 0.023 in.) for roof
molding to be maintained.
– Weld in roof, RP-spot weld seam.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
– Weld roof, SG-plug weld seam.

le
un
pt
an
d
itte
– Braze remaining joint.

y li
erm
ab
ility
– Grind SG-weld points down flush.

ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Seal roof channel (thin layer).

f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
Seal must be even and thin. Irregularities will be visible on roof

t
sd
iva
trim strip (wavy).

o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen o
Golf
Vol 1999 ➤ , GTI/Jetta 1999 ➤ot, gJetta
ksw es n
Wagon 1999 ➤
by ua
rised Body Repair ran- Edition 07.2007
t ee
tho or
au ac
2.2 Roof, Replacing, Jetta ss
ce
e
nl
pt
du
an
itte
y li
1 - Bonded area.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Cutting Location

1 - Roof cross member

– Cut out roof
– Clean out original bond
– Remove excess materi‐

al
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erm
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ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Replacement Part
nf
ercia
orm
♦ Roof
m
atio
om
n in

or c
thi
e

t
sd
iva
o
r
rp
cu
Welding in Place
o
m
f
en
ng
t.
yi Co
– Before welding in roof, apply Butyl adhesive sealing cord to Cop py
roof reinforcement.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

WARNING

WARNING
Check fit with windshield and rear window. It is essential that

dimension -a- = 13.2 ± 0.6 mm (0.519 ± 0.023 in.) for roof
molding to be maintained.
– Weld in roof, RP-spot weld seam.
Note
Seal must be even and thin. Irregularities will be visible won

ageroof
trim strip (wavy). lks es n
o ot g
yV u b ara
ed nte
oris e
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.3 Roof, Replacing, Jetta Wagon

l purpos

nf
ercia
♦ VAS5182 wire brush

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
A special hose package with reduced nozzle diameter is required

for the shielded gas welder in order to repair the roof:VAS5023
hose package VAS5023/2 - injector set
♦ compressed air - glue gun -VAG 2005-
Caution
Observe safety precautions!
1 - Glued area
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Separating Locations

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
– Drill out original bond to roof frame
cial p
f inform
– Grind through rear soldering points.

mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
pr
Brazing solder at vehicle must be completely ground off.

um
r
fo
en
ng
t.
yi Co
op
– Roughly cut out roof in area between C- and D-pillar.
C py
t. rig
gh ht
yri by
– Remove roof. cop Vo
by lksw
cted agen
Prote AG.
– Remove sealing compound from sealing channel.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Grind surface of laser weld seam and use chisel to bend up

remaining pieces and lever off.
Note
Only grind surface of laser weld seam. Do not grind through roof.
If the roof frame is damaged, it must also be replaced.
– Completely remove adhesive remains and grind bonding sur‐

face down to bare metal.
– Grind spot flanges down to bare metal from inside using a wire
brush.
Replacement Parts
♦ Roof
Preparing New Part

– For later SG plug weld seam, notches -magnifying glass- must

be ground into the horizontal roof flange using an angle grinder
or cutting grinder (distance approx. 45 - 50 mm).
. Volkswagen AG
gen AG does
– If necessary, drill holes for roof rail. Refer to Vol
ksw
a
not
⇒ “1.1 Roof Rail Dimensions”, page 78 . ed by gu
ara
ris nte
Welding In ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Apply butyl adhesive sealing cord -1- to front and rear of roof
reinforcement
t to the co
– Apply adhesive to roof frame before welding in.
rrectne
Caution
ss
New part must be installed within 30 minutes, otherwise bond‐
o
cial p
f
ing properties of adhesive will be impaired.
inform
mer
atio
om
n
c
i
or
n thi
Note
te
sd
iva
o
pr
cum
Check fit with windshield. It is essential to maintain dimension -a-
r
fo
en
ng
of 13.2 mm for roof trim molding.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
– Weld in roof, RP spot weld seam, SG plug weld seam.

m
at
om
io
– Braze remainder to rear joint of roof frame, optional SG step‐

n
c
in t
or
ped seam.
his
ate
do
riv
– Grind SG spot welds flush.

p
cum
for
en
ng
t.
yi Co
op py
Note . C rig
ht ht
rig by
copy Vo
The seal must be even and thin. Irregularities will be visible on
by lksw
cted agen
Prote
the roof trim strip (wavy).
AG.
2.4 Roof Front Crossmember, Replacing

♦ Roof removed

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Cutting Location ce
e
nl
pt
du
– Cut out cross member. an

itte
y li
erm
ab
ility
ot p
wit
, is n
Replacement Part
h re
hole
spec
♦ Roof cross member

es, in part or in w
t to the co
Welding in Place
– Position and secure cross member.
rrectness of i
– Weld in cross member, RP-spot weld seam.

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5 Roof Reinforcement, Replacing

♦ Roof removed.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Cutting Location
AG.
– Cut out roof reinforcement.

Note
Work process for Golf and Jetta is the same.
Replacement Part
Welding in Place

WARNING

– Weld cross member, RP-spot weld seam.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
2.6 Rear Roof Cross Member, Replacing,
spec
es, in part or in w
Golf
t to the co
♦ Roof already removed.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Body Repair - Edition 07.2007 en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Cutting Location
– Cut out cross member.
Replacement Part
Welding in Place
– Position and secure new part.
– Weld new part, RP-spot weld seam.

2.7 Rear Cross Member, Replacing, Jetta

♦ Roof removed
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
Cutting Location
wit
, is n
h re
– Cut out cross member.

hole
spec
es, in part or in w

t to the co
Replacement Part
rrectness of i
Welding in Place
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
95
AG.
2. Removal and Installation
– Weld in cross member, RP-spot weld seam.
2.8 Rear Roof Crossmember, Replacing,

Jetta Wagon
Caution
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
• Roof already cut out

– Roof crossmember, drilling out.
– Remove remaining material.
Replacement Part
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Rear roof crossmember

rrectne
Welding In
ss
– Spot weld roof crossmember, RP spot weld seam.

o
cial p
f inform
mer
atio
Note
om
n
c
i
or
♦ To spot-weld roof crossmember, only -VAG 1713- special tool

thi
te
sd
a
may be used due to strength related issues (3 panels of dif‐

iv
o
pr
ferent thicknesses in welding area).

um
r
fo
en
ng
t.
♦ When using other welding units, the roof crossmember must
yi Co
op py
be welded in using SG plug welding.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

2.9 A-Pillar, Replacing
1 - Foam treated area
Caution
Welding,
♦ separating, us‐ wage
es n
ing spark generating yV
olks ot g
ua
tools in foam treated rised b ran
areas creates gases,uth o tee
or
therefore, do not use
ss
a ac
these processes.
ce
le
un
pt
an
d
Use
♦ 2K-filler material to
itte
y li
smooth out irregularities.
rm
ab
pe
ility
ot
wit
, is n
– Scrape out as much ex‐
h re
hole
cess foam as possible
spec
before starting grinding
es, in part or in w
work.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Cutting Location

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Make parting cut -a- according to degree of damage.

– Make parting cut -b- as shown, do not damage internal rein‐
forcement.
rrectness of i

l purpos
Partial Replacement
nform
ercia
Due to an internal reinforcement parting cut -c- is only permissible

at this position.
m
at
om
ion
Reinforcement can be felt through round opening.

c
in t
or
his
te

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Replacement Part
♦ A-pillar lower section with sill
Preparing New Part
– Transfer separating lines to new part and cut out.

Welding in Place
– Adapt new part with vehicle standing on its wheels or on align‐
ment fixture and tack weld.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Weld in A-pillar, RP-spot weld seam.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
– Weld in A-pillar, SG-plug weld seam. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.10 Inner A-Pillar, Replacing
1 - Foam treated area

2 - Cutting line part sectionolkswage es n
ot g
yV ua
db ran
rise tee
Caution
tho or
s au ac
Welding,
♦ separating,
s us‐
ce
e
ing spark generating

nl
pt
du
an
tools in foam treated
itte
y li
areas creates gases,
erm
ab
therefore, do not use
ility
ot p
these processes.
wit
, is n
h re
hole
Use
♦ 2K-filler material to
spec
es, in part or in w
t to the co
Note
rrectness of i
– Scrape out as much
l purpos
foam as possible before

starting grinding work.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Cutting Location

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Separate original joint. ion

c
in t
or
his
e
Partial repair
at
do
priv
cum
or
A partial repair is possible using parting cuts -2- shown.

f
en
ng
t.
yi Co
– Remove excess material. t. Cop py
rig
gh ht
Replacement Parts yri
p by
o Vo
by c lksw
cted
♦ Inner A-pillar
agen
Prote AG.
♦ Insulation
Preparing New Part


Foam Insulation
Note repair instructions, refer to
⇒ “2.1 Body Foam Insulation”, page 3 .
Welding in Place
– Install new part with vehicle standing on its wheels or on align‐
– Check gaps/mating lines to adjacent parts. Volkswa
AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
ho eo
– Weld in inner A-pillar,aRP-spot
ut weld seam. ra
ss c
– Weld remaining joint, SG-plug weld seam.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.11 B-Pillar, Replacing, 4 Door and Jetta

1 - Bonded area lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Cutting Location
– Position parting cut according to degree of damage and cut
out.
– Cut through outer edge of wheel arch.
Note
♦ Record size of Replacement Part!

♦ Do not damage reinforcement in area of parting cut.


– Remove excess adhesive completely and grind adhesive sur‐
face back to bare metal.
Replacement Part
♦ Side panel frame lower section
Preparing New Part
– Transfer separating lines to new part and cut out shaded area.
– Ensure flange area is free of dust and grease.
– Apply adhesive to flange 2 beads each of 3.5 mm dia. (0.27

in.).
WARNING
AG. Volkswagen AG d
agen oes
lksw not
New part must be installed within 30 minutes, otherwise adhe‐ d by
Vo gu
ara
sive properties will be impaired. orise nte
eo
h
aut ra
ss c
ce
le
Welding in Place
un
pt
an
d
itte
y li
– Place backing plate behind weld seam and tack weld in posi‐
erm
ab
tion.
ility
ot p
wit
is n
– Install and secure new part with vehicle on wheels or fixture.
h re
ole,
– Check gap to mating part.
spec
– Weld inner A-pillar, RP-spot weld. t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


– Reform/compress wheel house flange.
– Remove excess adhesive and seal.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
2.12 Inner B-Pillar, Replacing, 2 Door ss c
ce
le
un
pt
• Side panel removed.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Cutting Location
Note
♦ Make parting cut -b- for side panel 100 mm (3.93 in.) under
roof edge.
♦ Make parting cut -a- for B-pillar 47 mm (1.85 in.) over mounting
point for seat belt, upper.

Replacement Part
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Inner B-pillar
Preparing New Part
– Make holes in reinforcement for new welds.
Welding in Place
– Install B-pillar with side panel and alignment fixture.

– Secure B-pillar to body

– Remove door hinge alignment fixture and side panel.
– Weld B-pillar, RP-spot weld, SG-plug weld.
– Weld B-pillar RP-spot weld seam, weld SG-continuous weld

seam.
Note AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
Missing spot welds in upper area areorwelded
ise when quarter panel nte
is welded. h eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Weld inner B-pillar, SG - continuous weld seam 4x25 mm
hole
spec
(0.157 x 0.98 in.)
es, in part or in w
t to the co
– Weld in 2 door side members (quarter panel). Refer to
⇒ “1.13 Quarter Panel, Partial Section Replacing, 2 Door”,
page 149 .
rrectness of i
– Weld in side member (quarter panel).

l purpos
nform
mercia
a
com
tion in
r
te o
thi
2.13 Inner B-Pillar, Replacing, 4 Door and

s
iva
do
r
rp
Jetta
um
fo
en
ng
t.
yi Co
op
Cutting Location C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Note Prote AG.
♦ Only complete replacement is possible

♦ Work procedure for Golf and Jetta is the same

1 - Bonded area
– Remove B-pillar -2-.
– Grind through outer

edge -1- at wheel arch
– Cut out rocker panel

-3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Drill out
ut inner roof frame -1- without damage.
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
109
by c lksw
cted
agen
Prote AG.
– Cut out excess material -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
– Grind out arc weld seam. du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Drill out remaining pieces.
orm
m
atio
Replacement Part
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Inner B-pillar
♦ Outer B-pillar
nform
ercia
Preparing New Parts

m
at
om
io
– Transfer separating lines to web plate and cut out.

n
c
in t
or
his
e
– Make holes in reinforcement for new welds.

at
do
priv
– Install and secure inner and outer B-pillars with door alignment
um
for
fixture. refer to
en
ng
t.
yi Co
⇒ “4.1.4 Alignment Brackets in Door Center Overview”, Cop py
page 49
t. rig
gh ht
pyri by
Vo
co
– Remove outer B-pillar.
by lksw
cted agen
Prote AG.
– Weld inner B-pillar, RP-spot weld seam, SG-continuous weld
seam, SG-plug weld seam.

– Weld inner B-pillar, SG-continuous weld seam 4x25 mm

(0.157 x 0.98 in.)
– Weld B-pillar in roof area, RP-spot weld, SG-plug weld
– Install panels -1- and -2- and secure.

– Weld panels, SG-plug weld seam.
Note
SG-plug welding should only be 15 mm (0.59 in.)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
– Weld in web plate, SG-continuous weld seam, SG-plug weld.

e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
Remaining spot welds will be welded when welding B-pillar.

hole
spec
es, in part or in w
– Welding B-pillar in, refer to

t to the co
⇒ “2.11 B-Pillar, Replacing, 4 Door and Jetta”, page 104 .

rrectness of i
l purpos
2.14 Outer Side Member, Replacing, 2 Door

nf
ercia
orm
Cutting Location
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
112
cted agen
Prote
Rep. Gr.51 - Body - Center, Chassis, Roof
AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Make sill parting cut according to degree of damage.
nform
ercia
– Drill out original joint to A-pillar.

m
a
com
tion in
r
te o
thi
Note
s
iva
do
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rp
cum
fo
Record size of Replacement Part!

en
ng
t.
yi Co
Cop py
.
ht rig
rig ht
py by
co Vo
Replacement Part
by lksw
cted agen
Prote AG.
♦ Side member (lower section)
Preparing New Part


Welding in Place
– Weld in side member, RP-spot weld seam.

– Butt weld parting cuts, SG continuous seam.
AG. Volkswagen AG d
– Weld in sill panel, SG-plug weld seam. lksw
agen oes
not
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nl
pt
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
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te
sd
iva
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f
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.15 Outer Side Member, Replacing, 4 Door and Jetta
1 - Bonded area
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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nl
pt
du
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Cutting Location
l purpos
– Make sill parting cut according to degree of damage.

nform
ercia
Note
m
at
om
ion
c
in t
Record size of Replacement Part!

or
his
ate
do
priv
– Cut through outer edge of wheel arch.

um
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.


– Remove adhesive completely and grind adhesive surface
back to bare metal.
Replacement Parts
♦ Side member (lower section)
Preparing New Part

– Ensure flange area is free of dust and grease.
– Apply adhesive to flange. 2 beads each 3.5 mm (0.137 in.)

diameter.
AG. Volkswagen AG d
WARNING agen oes
olksw not
byV gu
ara
ed
is nte
New part must be installed within 30thminutes,
or otherwise adhe‐ eo
sive properties will be impaired. ss au ra
c
ce
e
nl
pt
du
an
itte
Welding in Place
y li
erm
ab
ility

ot p
wit

, is n
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hole
spec
– Weld in side member, RP-spot weld seam.

es, in part or in w
t to the co
– Butt weld parting cuts, SG-continuous weld seam.

rrectness of i
– Remove excessive adhesive and seal.

l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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priv
2.16 Side Member Reinforcement, Replacing

um
for
en
ng
t.
yi Co
op
Including Web Plate Section C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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erm
ab
ility
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wit
, is n
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hole
spec
♦ Outer side member already removed
es, in part or in w
t to the co
Cutting Location
– With rear parting cut, cut strip out of side member reinforce‐
ment, then separate web plate. rrectness of i
l purpos

nf
ercia
Replacement Parts
orm
m
atio
m
♦ Side member reinforcement

o
n in
or c
♦ Web plate for side member

thi
te
sd
iva
Preparing New Part

o
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rp
cu
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m
f
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.


Welding in Place
– Install new part with vehicle standing on its wheels or on align‐ AG. Volkswagen AG d
ment fixture and tack weld. agen oes
olksw not
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ho eo
aut ra
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ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Weld side member reinforcement to side member web plate,
hole
spec
RP-spot weld seam.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Spot weld web plate, RP-spot weld.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Weld separating cut, SG-continuous weld seam.


– Secure strip and weld in, SG-continuous weld seam.

– Weld in side member. Refer to
⇒ “2.16 Side Member Reinforcement, Replacing”, page 116 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
2.17 Floor Plate, Partial Section, Replacing d b ara
rise nte
tho eo
u ra
Cutting Location ss a c
ce
e
nl
pt
du
an
itte
1 - Cutting line full section
y li
erm
ab
ility
2 - Cutting line part section
ot p
wit
, is n
– Cut out according to de‐
h re
hole
gree of damage.
spec
es, in part or in w
– Cut out floor panel.
t to the co
– Remove excess materi‐
al
rrectness of i
l purpos
Note
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
m
f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Partial Section
– At parting cut -2-, weld offset overlap both sides, SG-continu‐
ous weld seam staggered.
Replacement Parts
♦ Floor plate

♦ Seat cross member

♦ Guide rails
Preparing New Part
– Transfer parting lines to new part and cut.
– Add approx. 10 mm (0.393 in.) for overlap.
Welding in Place
– At parting line, offset overlap weld both sides, SG-continuous
weld seam (staggered).
– Align seat cross member, secure and weld in, RP-spot weld
seam.
– Weld in floor panel, RP-spot weld.
– Weld in seat cross member, RP-spot weld seam.

– Weld in seat guide rail, SG-continuous weld seam.
. Volkswagen AG
– Weld in seat guide rail, RP-spot weldksseam.
wage
n AG does
not
ol
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edb ara
ris nte
tho eo
au ra
c
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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b
53 – Body - Rear
d ara
rise nte
tho eo
au ra
ss c
ce
e
1 Removal and Installation

nl
pt
du
an
itte
y li
erm
⇒ “1.1 Rear Cross Panel, Replacing”, page 121
ab
ility
ot p
⇒ “1.2 Rear Cross Panel, Exterior, Replacing, Jetta Wagon”, page
wit
, is n
122
h re
hole
spec
⇒ “1.3 Rear Cross Panel, Complete, Replacing, Jetta Wagon”,
es, in part or in w
page 125
t to the co
⇒ “1.4 Tail Lamp Cluster Mount, Replacing, Golf”, page 132
rrectness of i
⇒ “1.5 Rear Center Cross Panel Carrier, Replacing, Jetta”,
page 135
l purpos
⇒ “1.6 Rear Cross Panel, Replacing, Jetta”, page 137
nform
ercia
⇒ “1.7 End Cross Panel, Replacing, Golf”, page 139

m
⇒ “1.8 Outer Wheel Housing, Replacing, Jetta”, page 140
at
om
ion
c
⇒ “1.9 C-Pillar Reinforcement, Replacing, Jetta Wagon”,
in t
or
his
e
page 142
at
do
priv
c
⇒ “1.10 Rear Longitudinal Member, Partial Section Replacing,
um
for
en
g
Golf”, page 143

n
t.
yi Co
op py
⇒ “1.11 Rear Longitudinal Member, Replacing, Jetta”,
t. C rig
gh ht
yri
page 145 p by
co Vo
by lksw
cted agen
⇒ “1.12 Longitudinal Member, Partial Section Replacing, Jetta”, Prote AG.
page 147
page 149
⇒ “1.14 Quarter Panel, Partial Section, Golf 4 Door, Replacing”,
page 151
⇒ “1.15 Quarter Panel, Partial Section Replacing, Jetta”,
page 154
⇒ “1.16 Side Panel, Partial Section Replacing, Jetta Wagon”,
page 157
⇒ “1.17 Quarter Panel, Partial Section, Replacing, Golf”,
page 161
⇒ “1.18 Wheel Housing Connection Panel, Partial Section Re‐
placing, Jetta”, page 163
⇒ “1.19 Connecting Panel, Replacing, Jetta”, page 164
⇒ “1.20 Outer Rear Wheel Housing, Partial Section Replacing,
Jetta Wagon”, page 166
⇒ “1.21 Spare Wheel Well, Replacing, Golf”, page 168
⇒ “1.22 Spare Wheel Well, Partial Section Replacing, Golf”, page
170
⇒ “1.23 Spare Wheel Well, Replacing, Jetta”, page 171
1.1 Rear Cross Panel, Replacing

♦ Rear cross panel carrier removed

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an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Cutting Location
– Separate rear cross panel original joint.
1.2 Rear Cross Panel, Exterior, Replacing,

Jetta Wagon
♦ wire brush -VAS 5182-
122 Rep. Gr.53 - Body - Rear

Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c

thi
te
sd
iva
– Cut out rear cross panel.

o
r
rp
cu
o
m
f
en
– Grind welding area to bare metal from inside using wire brush
ng
t.
yi Co
-VAS 5182- . ht. Cop py
rig
rig ht
Replacement Parts py by
co Vo
by lksw
cted agen
♦ Rear cross panel, outside Prote AG.

Preparing New Part

– Drill 8 mm holes for SG plug weld seam.

Welding In
– Apply butyl adhesive sealing cord -1- to longmembers.

– Weld in rear cross panel, RP spot weld seam, SG plug weld
seam.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
124
Prote AG.
Rep. Gr.53 - Body - Rear
lkswage es n
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un
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an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
– Braze remaining bond to mount for SBBR-lamp.
gh ht
pyri by
Vo
co lksw
by
1.3 Rear Cross Panel, Complete, Replac‐
cted agen
Prote AG.
ing, Jetta Wagon

⇒ “1.3.1 Lock Carrier, Welding”, page 127
⇒ “1.3.2 Interior Side Panel, Installing”, page 128
⇒ “1.3.3 Lower D-Pillar Reinforcement, Installing”, page 129
⇒ “1.3.4 D-Pillar Reinforcement”, page 130
⇒ “1.3.5 Inner D-Pillar Reinforcement, Installing”, page 130
⇒ “1.3.6 Tail Lamp Mount, Installing”, page 131
⇒ “1.3.7 Cross Member, Welding to Rear Cross Panel from Inside
”, page 132

♦ wire brush -VAS 5182-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Caution rise
d
nte
tho eo
au ra
Observe safety precautions! ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
• Rear cross panel, exterior and side panel already removed.
ot
wit
, is n
h re
– Drill out transverse beam at rear cross panel from inside.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
– Drill out mount for SBBR-lamp.
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer

atio
om
– Separate rear cross panel and parts of D-pillar.

c
i
or
n thi
te
sd
a
1.3.1 Lock Carrier, Welding

iv
o
pr
cum
r
fo
Replacement Parts
en
ng
t.
yi Co
op py
♦ Lock carrier t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
Preparing New Part
– Transfer separating cut plus 20 mm to new part for overlap in
spot weld area -a-, and separate hatched area.
– Step new part in spot weld area -a-.
– Align and secure new part.

– Apply adhesive in spot weld area -a-.
Caution

. Volkswagen AG
gen AG does
swa
– Weld in new part, RP spot weld seam, SG plug weld seam. y Volk not
gu
edb ara
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3.2 Interior Side Panel, Installing
rrectness of i
Replacement Parts
l purpos
♦ Inner side panel
nform
ercia

m
a
com
t
Preparing New Part
ion in
r
te o
– Transfer separating cuts plus 20 mm to new part for overlap
thi
s
iva
in spot weld areas -a- and separate hatched area.
do
r
rp
cum
fo
– Step new part in spot weld area -a-. en

ng
t.
yi Co
op
– Align and secure new part. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Apply adhesive in spot weld area -a-.
Caution


– Weld in side panel from inside, RP spot weld seam, SG plug

weld seam.
– Weld in remainder of joint, SG continuous seam.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
1.3.3 Lower D-Pillar Reinforcement, Installing
ole,
spec
Replacement Part
t to the co
♦ Reinforcement for D-pillar, lower
rrectne
Preparing New Part
– Drill holes for SG plug weld seam.
ss o
– Align and secure new part.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Clean spot weld area through oval hole -1- using wire brush.
– Weld in reinforcement for lower D-pillar, RP-spot weld seam,

SG-plug weld seam

1.3.4 D-Pillar Reinforcement

Replacement Part
♦ Reinforcement for D-pillar
Preparing New Part
– Transfer separating cut to new part and cut off hatched area.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Weld in new part, RP spot weld seam, SG stepped seam.

– Weld remaining joint, SG plug weld seam.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.3.5 Inner D-Pillar Reinforcement, Installing

Replacement Part
♦ Reinforcement for D-pillar, inner

Preparing New Part

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d ran
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tho
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a ac
ss
ce
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un
pt
an
d
itte
y li
rm
ab
pe
ility
– Weld in reinforcement, RP spot weld seam.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
1.3.6 Tail Lamp Mount, Installing
cted agen
Prote AG.
Replacement Part
♦ Mount for SBBR lamp.
– Weld in new part, RP spot weld seam.

1.3.7 Cross Member, Welding to Rear Cross

Panel from Inside
Replacement Part
♦ Crossmember to rear cross member, inside
– Weld in rear cross panel, outer.
– Weld in side panel.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
♦ Rear cross panel
wit
is n
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Welding in Place
ole,
spec

t to the co
– Check tailgate lock function. rrectness o
cial p
f inform
mer
– Spot weld rear cross panel, RP spot weld seam.

atio
om
– Weld in cross panel.

n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
1.4 Tail Lamp Cluster Mount, Replacing,

Golf
• Rear cross panel removed

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Cutting Location
Separating Left Inner
– Drill out original joint with spot weld drill bit.
Separating Right Inner

– Separate joint to wheel house.

– Make separating cut with body saw VAG1523.
– Offset body side.

Replacement Part
♦ Tail light mount
Preparing New Part
AG. Volkswagen AG d
agen oes
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– Make holes in flange of new by part.
Vol
gu
ara
ed
is nte
– Weld new part in, RP-spot
hor
weld seam. eo
aut ra
s c
Welding in Place s
ce
e
nl
pt
du

an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Weld in cross panel, RP-spot weld seam.

rrectness of i

l purpos
Welding in Left Inner

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Weld in cross panel, RP-spot weld seam.

n AG. Volkswagen A ge G do
swa es n
Welding in Right Inner
by
Vol
k ot g
ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– At parting cut, make overlap weld, SG continuous seam (stag‐
es, in part or in w
t to the co
gered).
– Weld in sealing plate. Refer to
⇒ “1.3.7 Cross Member, Welding to Rear Cross Panel from
rrectness of i
Inside ”, page 132 .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.5 Rear Center Cross Panel Carrier, Re‐

placing, Jetta

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Cutting Location
lksw
cted agen
Prote AG.
– Bend quarter panel out and away from end points (highlighted)
(arrows).
Replacement Part
♦ Lower rear panel
♦ End cross member
Installing

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Guide close out panel behind areas -1- and -2- mount for tail spec
es, in part or in w
light asm. t to the co
– Install and secure rear closeout panel aligning it with trunk lid.
Welding in Place
rrectness of i
– Spot weld close out panel, RP spot weld.

l purpos
– Align quarter panel end points to closeout panel and weld, SG-
plug weld seam.
nform
ercia
– Weld end cross member.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.6 Rear Cross Panel, Replacing, Jetta
Cutting Location

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
– Bend quarter panel out and away from end points (highlighted)
t. rig
gh ht
yri
(arrows)
p by
o Vo
by c lksw
cted agen
Prote AG.
Replacement Part
♦ Tail light assembly mount
♦ Lower back panel
Welding in Place
– Install and align new parts.

– Spot weld close out panel, RP-spot weld seam

– Remaining bond, SG-plug weld.
– Weld close out panel
– Weld end cross member
AG. Volkswagen AG d
agen oes
lksw not
1.7 End Cross Panel, Replacing, Golf Vo gu
d by ara
ise nte
or eo
h
Cutting Locations aut ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Replacement Part
Welding in Place
– Install and secure new part.
– Check trunk lid lock function.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
1.8 Outer Wheel Housing, Replacing, Jetta
erm
ab
ility
ot p
wit
Cutting Location
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Replacement Part
Welding in Place
– Install and secure new part.

1.9 C-Pillar Reinforcement, Replacing, Jet‐

ta Wagon
Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
• Side panel already cut out

– Drill out reinforcement for C-pillar.
Replacement Part

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
♦ Reinforcement for C-pillar

en
ng
t.
yi Co
op
Welding In
C py
t. rig
gh ht
yri by
– Weld in new part, RP spot weld seam. cop Vo
by lksw
cted agen
Prote AG.
– Weld in side panel (Wagon).
1.10 Rear Longitudinal Member, Partial Sec‐

tion Replacing, Golf
♦ Close out panel and tail light assembly mount removed

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Cutting Location
orm
m
atio
om
n in
Caution
or c
thi
te
sd
a
Take care working near fuel tank when removing right longitu‐
iv
o
r
rp
cu
dinal member reinforcement

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
– Drill out longitudinal member rig ht
py by
co Vo
by lksw
– Separate original joint cted agen
Prote AG.

Replacement Part
♦ Rear longitudinal member

Preparing New Part

Welding in Place
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Weld in longitudinal member, SG-plug weld seam.
wit
is n
h re
ole,
– Spot weld rear longitudinal member, RP-spot weld.
spec
– Butt weld parting cut, SG-continuous seam.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
1.11 Rear Longitudinal Member, Replacing,
i
or
n thi
te
sd
Jetta
iva
o
pr
cum
r
fo
♦ Close out panel and taillight assembly mount removed
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
Cutting Location t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted
Caution
agen
Prote AG.
– Drill out longitudinal member

Replacement Part
♦ Rear longitudinal member
Welding in Place

– Weld longitudinal member, RP-spot weld.
1.12 Longitudinal Member, Partial Section

Replacing, Jetta
♦ Cross panel and tail light mount already cut out
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Cutting Location
Caution
– Drill out forward original joint to floor plate.

– Remove remaining material
Replacement Part
♦ Longitudinal member
♦ Rear longitudinal member agen
AG. Volkswagen AG d
oes
olksw not
♦ Adhesive butyl ADL 450 005 05 d by V gu
ara
rise nte
o
♦ Dampener/insulation auth eo
ra
ss c
Preparing New Part
ce
e
nl
pt
du
an
itte
y li
erm
ab
Welding in Place
ility
ot p
wit
, is n
– Position longitudinal member relative to adjoining parts and
h re
secure.
hole
spec
es, in part or in w
– Butt weld longitudinal member, SG-plug weld seam.
t to the co
– Spot weld rear longitudinal member, RP-spot weld.
– Apply butyl adhesive to dampener/insulation and press onto
rrectness of i
longitudinal member.
l purpos
– Spot weld rear longitudinal member.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.13 Quarter Panel, Partial Section Replacing, 2 Door
1 - Bonded area
2 - Partial replacement cutting
AG. Volkswagen AG d
line ksw
agen oes
not
Vol
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Cutting Location
– Transfer separating lines to B and C-pillars depending on de‐
gree of damage.
– Grind through outer edge at wheel opening.
– Roughly cut out.
Partial repair
A partial repair is possible using parting cuts -2- shown.
♦ AP-Nr: 53 64
– Make separation cut above wheel house with VAG1523

– Remove residue.
– Remove adhesive residue completely and grind surface
smooth.
Replacement Part
♦ Partial quarter panel
Preparing New Part
– Transfer separation lines to new part and separate from high

lighted area.
– Drill new part in flange area.
– Drill holes for welding, SG-plug weld 7 mm dia. (0.27 in.)
– Clean flange.
– Apply 2 - 3.5 mm dia.(0.14 in.) beads of adhesive.
WARNING
New part must be welded with in 30 min., otherwise adhesion

properties are affected.
Welding in Place
AG. Volkswagen AG d
agen oes
– Place backing material behind weld seams.
Vol
ksw not
gu
by ara
ed
– Install and secure new parts with ovehicle
ris on wheels or fixture. nte
eo
th
au ra
– Check gaps/mating lines. ss c
ce
e
nl
pt
du
an
– Weld quarter panel, RP-spot weld seam.

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
150
co Vo
by lksw
Rep. Gr.53 - Body - Rear cted agen
Prote AG.
– Butt weld seam, SG-weld continuous seam

– Weld remaining seam, SG-plug weld seam.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
1.14 Quarter Panel, Partial Section, Golf 4 Door, Replacing
erm
ab
ility
ot p
wit
, is n
h re
1 - Foamed Area
hole
spec
2 - Bonded area
es, in part or in w
t to the co
Caution
rrectness of i
Welding,
♦ separating us‐
ing spark generating
l purpos
tools in the foam area

creates gases, therefore,
do not use these pro‐
nf
ercia
o
cesses.
rm
m
atio
m
Use
♦ 2K filler material to
o
n in
c

or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op py
– Before performing . C rig
ht ht
grinding work scrape
rig by
opy Vo
out as much foam resi‐ by c lksw
cted agen
due as possible.
Prote AG.
Cutting Location

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
– Make cut to C-pillar according to degree of damage.

e
nl
pt
du
an
itte
– Make lower cut above rocker panel.

y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Record Replacement Part cut.

es, in part or in w
t to the co
– Roughly cut out quarter panel.

rrectness of i
– Grind outer edge of wheel house.

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove residue
– Completely remove adhesive residue and grind surface
smooth.
Replacement Part
♦ Adhesive DA 001 730 A1
♦ Dampener/insulation agen
AG. Volkswagen AG d
oes
olksw not
V gu
Preparing New Part ed by ara
nte
ris
ho eo
aut ra
ss c
ce
le
– Transfer separation lines to new part and cut out high lighted
un
pt
area.
an
d
itte
y li
erm
ab
– Drill holes in flange area of new part.
ility
ot p
wit
– Clean/degrease flange.
is n
h re
ole,
Foamed Area
spec
Repair notes ⇒ “2.1 Body Foam Insulation”, page 3 .
t to the co
rrectness o
cial p
– Apply 2 - 3.5 mm dia. (0.14 in.) beads adhesive to flange.
f inform
mer
atio
WARNING
om
n
c
i
or
n thi

te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Welding in Place C py
t. rig
gh ht
yri by
– Place support material behind weld joints. op Vo
by c lksw
cted agen
Prote
AG.
– Check gaps/mating lines dimensions with adjacent parts.
– Butt weld cut, SG-weld seam continuous.

– Weld remainder, SG-plug weld seam.

– Weld quarter panel, RP-spot weld.

– Wipe off excess adhesive and seal.
1.15 Quarter Panel, Partial Section Replac‐

ing, Jetta
Cutting Location
1 - Reinforcement
❑ Sits directly behind high
lighted area.
2 - Dampener/insulation
❑ Combined reinforce‐
ment -1- and quarter
panel, partial replace‐
ment cutting line
3 - Foamed Area
4 - Bonded area
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
is Golf 1999 ➤ , GTI/Jetta 1999 ➤ , Jetta nte
hor eWagon 1999 ➤
ut or
ss a Body Repair - Edition
ac 07.2007
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Study Replacement Part blank
, is n
h re
hole
♦ Separation cuts made only with body saw VAG1523 or with
spec
air hammer VAG1577.
es, in part or in w
t to the co
WARNING
rrectness of i
♦ Welding, separating using spark generating tools in the
l purpos
foam area creates gases, therefore, do not use these pro‐

cesses.
nf
ercia
o
♦ Use 2-K filler material to smooth out irregularities.
rm
m
atio
om
n in
or c
thi
– Place lower separating cut above rocker panel.
te
sd
iva
o
r
– Grind wheel house outer edge.

rp
cu
o
m
f
en
ng
– Roughly cut out quarter panel.

t.
yi Co
Cop py
t. rig
– Remove excess material. opyri
gh by
Vo
ht
by c lksw
– Remove adhesive residue completely and grind flange smooth Prote
cted agen
and clean
AG.
Replacement Part
♦ Dampener/insulation
♦ Adhesive butyl AKL 450 005 05
♦ AKD 476 KD5 05
Preparing New Part
– Transfer separating lines to new part and cut out high lighted
area.
– Drill new part in flange/contact area.
– Clean/degrease flange area.
Foamed Area

– Bond dampener/insulation -1- both sides with butyl bead and

press securely to C-pillar reinforcement.
– Apply AKD 476 KD5 05 on lower edge for striker reinforcement
(on quarter panel).
– Apply 2 - 3.5 mm dia. (0.14 in.) beads of adhesive on flange

-2-.
Note
Observe repair notes, refer to

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
WARNING rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte
y li
rm
ab
pe
ility
Welding in Place
ot
wit
, is n
h re
hole
spec
– Check gaps/mating lines dimensions with adjacent parts.

es, in part or in w
t to the co
Note
rrectness of i
Before welding right quarter panel, apply bead of butyl -1- at fuel
l purpos
filler neck area.

nform
ercia
– Butt weld seam, SG-weld continuous seam

m
a
com
tio
– Weld remaining seam, SG-plug weld seam.

n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


– Wipe off excess adhesive and seal.
– Weld quarter panel, RP-spot weld, SG-plug weld.
Note
Fuel filler neck area must be sealed additionally with AKD 476
KD5 05
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.16 Side Panel, Partial Section Replacing,

Jetta Wagon
rrectness of i
l purpos
Caution
nform
ercia
Observe safety precautions! Refer to ⇒ General Information;

Body Repairs, Body Collision Repair
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Reinforcement
❑ is located directly below
the indicated upper sep‐
arating cut -a- = max.
270 mm
2 - Glued area
3 - Foam filled area
❑ is located directly be‐
hind the indicated upper
separating cut
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Note
spec
♦ Observe replacement panel separating cut!

t to the co
♦ Only perform separating cuts using VAG1523 body saw or

VAG1577 pressure hammer!
rrectness
Caution
o
cial p
f inform
Avoid these procedures, since gases which are health-haz‐

mer
ardous for humans and environment originate during welding,

atio
m
separating with spark generating appliances/tools or galvaniz‐

o
n
c
i
or
ing in Foamed Areas.

thi
te
sd
va
Use a 2-K spackling compound to even out dents.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Perform bottom separating cut above sidemember.
. C rig
ht ht
rig by
py
– Grind through outer edge of wheelhousing.
co Vo
by lksw
cted agen
Prote AG.
– Roughly cut side panel.
– Remove remaining material.

– Completely remove adhesive remains and grind bonding sur‐

face down to bare metal.
Replacement Parts
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
♦ Side panel sub-part

wit
, is n
h re

hole
spec
es, in part or in w

t to the co
♦ Polyurethane-adhesive sealing compound AKD 476 KD5 05

Preparing New Part
rrectness of i
– Transfer separating cut to new part and cut off hatched area.
l purpos
– Make holes in outer joint surface of new part.

nform
ercia
– Clean flanged area (it must be free of dust and grease).

m
– Apply butyl adhesive sealing cord -1- on reinforcement for

com
tion in
striker
r
te o
thi
s
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Welding In
Note
For the right side panel, butyl adhesive sealing cord -1- must be
applied to the wheelhousing outer around the opening of the tank
filler flange.
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– Flange wheel flange -1-.

– Wipe off escaping adhesive and seal.
– Weld in side panel, RP spot weld seam, SG plug weld seam.

– Weld separating cut, SG stepped seam.
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After welding in the right side panel, the area of the tank filler
t to the co
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1.17 Quarter Panel, Partial Section, Replac‐

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♦ Quarter panel removed

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Cutting Location
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– Make parting cut so body side can be offset.

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Replacement Part
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Welding in Place
– Check gaps/mating lines at wheel house, with quarter panel
installed and vehicle stress free.


– Weld quarter panel (2-door). Refer to
page 149
– Weld quarter panel (4-door). Refer to
⇒ “1.14 Quarter Panel, Partial Section, Golf 4 Door, Replac‐
ing”, page 151
1.18 Wheel Housing Connection Panel, Par‐

tial Section Replacing, Jetta
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Cutting Location
– Make parting cut so body side can be offset.
Replacement Part

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♦ Wheel house
Preparing New Part
Welding in Place
– Check gaps/mating lines at wheel house, with quarter panel
installed and vehicle stress free.
– Weld wheel house (Jetta). Refer to
⇒ “1.20 Outer Rear Wheel Housing, Partial Section Replacing,
Jetta Wagon”, page 166
1.19 Connecting Panel, Replacing, Jetta


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Cutting Location
– Remove connecting panel.
Replacement Part
♦ Connecting panel
Welding in Place
– Weld connecting panel, RP-spot weld

1.20 Outer Rear Wheel Housing, Partial Sec‐

tion Replacing, Jetta Wagon
Caution
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– Drill out corner panel for luggage compartment floor -1- from
m
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wheelhousing liner.
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– Drill through fillet plate -2- and remove from wheelhousing lin‐
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Replacement Parts
♦ Outer wheelhousing liner
Preparing New Part
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– Transfer separating cut plus
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– Fit wheelhousing liner and check gap dimensions with side

panel installed and with vehicle free of stress.
– Step on body side.

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– Weld in new spart, RP spot weld seam.
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du
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– Install fillet plate -2- to wheelhousing liner and weld in, SG plug
weld seam.
– Braze inner seam to wheelhousing
– Weld in reinforcement for C-pillar. Refer to
⇒ “1.9 C-Pillar Reinforcement, Replacing, Jetta Wagon”, page
142 .
– Weld in side panel (Wagon).
1.21 Spare Wheel Well, Replacing, Golf

♦ Cross panel and tail light mount removed

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Cutting Location
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– Drill out forward original joint to floor panel.

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Preparing New Part
– Drill new part in outer flange area.
Welding in Place
– Check gaps/mating lines.

– Weld remainder, SG-plug weld seam.

– Weld at connection to floor, SG-continuous seam staggered
– Weld mount for tail light assembly. Refer to
⇒ “1.4 Tail Lamp Cluster Mount, Replacing, Golf”, page 132 .
Note
olkswagen AG
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Secure new vehicle information label
olksin spare tire wheel well after
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Preparing New Part
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Welding in Place
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– Weld new part, SG-plug weld seam.
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fo
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⇒ “1.3.7 Cross Member, Welding to Rear Cross Panel from

t.
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Inside ”, page 132
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Secure new vehicle information label in spare tire wheel well after
paint work is completed.
1.23 Spare Wheel Well, Replacing, Jetta


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Note
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♦ Take care when cutting out spare wheel well that reinforce‐
ion
c
ments -1- and -2- are not damaged since they are located
in t
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directly underneath.
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♦ Carefully drill out welds with spot weld cutter VAG1731 as far
um
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as possible.
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– Remove adhesive residue completely and grind surface

smooth.
Replacement Part
♦ Tow hooks
♦ Dampener/insulation
♦ Adhesive bead AKL 450 005 05


Preparing New Part
– Drill new holes in flange.
– Spot weld tow hooks at spare wheel well, RP-spot weld.
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ot
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♦ SG-spot weld should be placed 15mm (0.59 in.) apart to main‐
tain factory produced integrity.
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♦ SG-spot welds should be made from the outside for optical
reasons.
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– Bond deadener -1- with Butyl bead all around and press in
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– Apply adhesive -2-.
WARNING

Welding in Place

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– Weld quarter panel, RP-spot weld seam.

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Begin SG-spot welding -1-, -2-, and -3- from the outside
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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
gen AG
. Volkswagen AG
wa does
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•= If you are going to work under a vehicle on the ground, imakesed sure that the ground is level. Block arathe wheels
nte to
or e o from
keep the vehicle from rolling. Disconnect the batteryunegative
th terminal (ground strap) to prevent others ra
a c
starting the vehicle while you are under it. ss
ce
le
un
pt
an
d
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
itte
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erm
ab
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
ility
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being fully alert.
wit
is n
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
spec
t to the co
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
rrectne
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
ss
injury could result.

o
cial p
f inform
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
mer
atio
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
om
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
n
c
i
or
new parts where indicated, and any other time it is deemed necessary by inspection.
thi
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Page 1 of 3by co Vo
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© 2002 Volkswagen of America, Inc. cted agen
Prote AG.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
AG. Volkswagen AG d
automotive chemical refrigerants. swagen oes
lk
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yV ua
edb ran
•= Before doing any electrical welding on is
rvehicles equipped with anti-lock brakes tee disconnect
(ABS), the battery
tho
u the ABS control module connector. or
negative terminal (ground strap) and a ac
ss
ce
e
nl
pt
du
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
an
itte
y li
system pressure and may cause the system to burst.

erm
ab
ility
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•=
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When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
, is n
h re
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
hole
spec
components is not separately fused, disconnect the control module connector(s).

es, in part or in w
t to the co
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
rrectness of i
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
l purpos
should test, disassemble or service the airbag system.

nform
mercia
at
om
ion
c
in t
or
Page 2 of 3
his
ate
do
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© 2002 Volkswagen of America, Inc.

p
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i t.
the prior expressed written permission of the publisher. py Co
Version 1.0 t. Co py
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Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
AG. Volkswagen AG d
agen oes
lksw not
•= Never use a test light to conduct electrical tests b
o
y Vof the airbag system. The system gu must only be tested by trained
ara
ed
Volkswagen Service technicians using theoriVAG s 1551 Scan Tool (ST) or an approved ntequivalent.
ee The airbag unit
must never be electrically tested while aituthis not installed in the vehicle. or
a
ss c
ce
le
un
•=
pt
Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
an
d
itte
y li
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
erm
ab
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
ility
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tire from the rim before attempting any repair.
wit
is n
h re
ole,
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
spec
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
t to the co
rrectne
I have read and I understand these Cautions and Warnings.
ss o
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© 2002 Volkswagen of America, Inc.
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D3E801425F8-Body Repair

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Copyright:

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D3E801425F8-Body Repair

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Service

Jetta Wagon 1999 ➤

Service Department. Technical Information

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Copyright © 2008 Volkswagen AG, Wolfsburg D3E801425F8

1.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Reinforced Body Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Straightening Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.2 Intermediate Piece, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.3 Fender Connecting Plate, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.4 Longitudinal Member, Upper Wheel Housing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 64

51 - Body - Center, Chassis, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

53 - Body - Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1.3 Rear Cross Panel, Complete, Replacing, Jetta Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

00 – General, Technical Data

1.1 Technical Data

Information label is located on the front longitudinal member

Vehicle information label contains:

Vehicle Data Label, Jetta from 04.00

rear left wheelhouse.

2 Rep. Gr.00 - General, Technical Data

2 Description and Operation

Foam treating reduces noise transfer to the interior.

shop conditions, proceed as follows:

placement is correctly prepared.

– Remove excess foam material.

– Repaint, apply two coats (wet on wet) glass/paint primer D009

200 02 if necessary, flash-off time - approx.10 min.

– Install insulation on vehicle.

2.2 Reinforced Body Sheet Metal

2. Description and Operation 3

2.3 Laser Welding

4 Rep. Gr.00 - General, Technical Data

2.4 Galvanized Body Panels

2. Description and Operation 5

3.1 Body Panel Gaps

3.1.1 Body, Front, Golf

6 Rep. Gr.00 - General, Technical Data

D - 2.0 mm (0.078 in.)

F - 3.0 mm (0.118 in.)

H - 4.0 mm (0.157 in.)

K - 5.0 mm (0.196 in.)

3.1.2 Body, Rear, Golf

Special tools and workshop equipment required

♦ Adjustment gauge -3371-

D - 2.0 mm (0.078 in.)

8 Rep. Gr.00 - General, Technical Data

A - 2.0 mm (0.078 in.)

F - 3.5 mm (0.137 in.)

H - 4.0 mm (0.157 in.)

3.1.3 Body, Front, Golf from 2008

The clearance measurements are always indicated in mm.

♦ Use the adjustment gauge -3371- to adjust and control the

10 Rep. Gr.00 - General, Technical Data

3.1.4 Rear Side, from 2008

♦ Use the adjustment gauge -3371- to adjust and control the

12 Rep. Gr.00 - General, Technical Data

Special tools and workshop equipment required

♦ Adjustment gauge -3371-

A - 0.5 mm (0.019 in.)

B - 1.0 mm (0.038 in.)