2005 Volkswagen Jetta Body Repair Manual – PDF DOWNLOAD
FILE DETAILS:
2005 Volkswagen Jetta Body Repair Manual – PDF DOWNLOAD
Language : English
Pages : 229
Downloadable : Yes
File Type : PDF
Size: 6.95 MB
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
2005 Volkswagen Jetta Body Repair Manual – PDF DOWNLOAD
00 – Technical data 7
1 Vehicle identification data 7
1 1 Vehicle identification number 7
1 2 Identification plate 8
1 3 Vehicle data sticker 8
2 Safety instructions 10
3 Moulded foam elements 11
4 Laser welding 12
5 Galvanized body parts 13
5 1 Body 13
5 2 Floor group 14
6 High strength body parts 15
6 1 Body 15
6 2 Floor group 16
7 Body panel gaps/shut lines 18
7 1 Body – front 18
7 2 Body – centre 20
7 3 Body – rear 21
8 Body dimensions 24
8 1 Body – front 24
8 2 Body – centre 29
8 3 Body – rear 34
8 4 Floor group – front 37
8 5 Floor group – centre 40
8 6 Floor group – rear 42
9 Alignment jig 45
9 1 Overview 46
9 2 Front alignment bracket 47
9 3 Centre alignment bracket 52
9 4 Rear alignment bracket 54
10 Portal gauge 56
10 1 Overview 56
10 1 1 Front door aperture 56
10 1 2 Rear door aperture 57
50 – Body – front 58
1 Renewing right-hand bracket 58
1 1 Removing 58
1 2 Installing 59
1 2 1 Welding in 59
2 Renewing left console 61
2 1 Removing 62
2 2 Installing 63
2 2 1 Preparing new part 63
2 2 2 Welding in 63
3 Renewing retaining bracket 64
3 1 Removing 64
3 2 Installing 65
3 2 1 Preparing new part 65
3 2 2 Welding in 65
4 Renewing front bumper bracket 67
4 1 Removing 67
4 2 Installing 68
4 2 1 Welding in 68
5 Renewing upper wheel housing longitudinal member 70
5 1 Removing 71
5 2 Installing 71
5 2 1 Preparing new part 71
5 2 2 Welding in 71
6 Renewing upper longitudinal member for wheel housing – partial renewal 73
6 1 Removing 73
6 2 Installing 74
6 2 1 Preparing new part 74
6 2 2 Welding in 75
7 Renewing front wheel housing 76
7 1 Removing 76
7 2 Installing 77
7 2 1 Preparing new part 77
7 2 2 Welding in 77
8 Repairing threads for securing subframe (suspension subframe) 78
8 1 Contents of thread repair kit 79
8 2 Repairing thread 80
8 2 1 Drilling thread 80
8 2 2 Cutting thread 81
8 2 3 Inserting thread insert 81
9 Renewing front longitudinal member 83
9 1 Removing 84
9 2 Installing 86
9 2 1 Preparing new part 86
9 2 2 Welding in 87
9 2 3 Shortening new longitudinal member with cover plate 88
10 Renewing front longitudinal member – partial replacement 91
10 1 Removing 92
10 2 Installing 93
10 2 1 Preparing new part 93
10 2 2 Welding in 93
10 2 3 Shortening new longitudinal member with cover plate 94
51 – Body – centre 95
1 Renewing roof 95
1 1 Removing 96
1 2 Installing 97
1 2 1 Preparing new part 97
1 2 2 Adjusting roof depth 101
1 2 3 Bonding roof 102
1 2 4 Welding in 106
2 Renewing front roof cross member 108
2 1 Removing 108
2 2 Installing 109
2 2 1 Welding in 109
3 Renewing roof reinforcement 111
3 1 Removing 111
3 2 Installing 112
3 2 1 Welding in 112
4 Renewing rear roof cross member 113
4 1 Removing 113
4 2 Installing 114
4 2 1 Welding in 114
5 Renewing A-pillar – partial renewal 116
5 1 Removing 118
5 2 Installing 119
5 2 1 Preparing new part 119
5 2 2 Moulded foam elements 119
5 2 3 Welding in 120
6 Renewing A-pillar reinforcement 122
6 1 Removing 124
6 2 Installing 125
6 2 1 Preparing new part 125
6 2 2 Moulded foam elements 125
6 2 3 Welding in 126
7 Renewing B-pillar 128
7 1 Removing 131
7 2 Installing 133
7 2 1 Preparing new part 133
7 2 2 Marking area where no welding work may be carried out 134
7 2 3 Moulded foam elements 134
7 2 4 Welding in 135
8 Renewing B-pillar reinforcement 138
8 1 Removing 140
8 2 Installing 143
8 2 1 Preparing new part 143
8 2 2 Marking areas where no welding work may be carried out 146
8 2 3 Moulded foam elements 146
8 2 4 Welding in 147
9 Renewing side member 151
9 1 Removing 153
9 2 Installing 154
9 2 1 Preparing new part 154
9 2 2 Moulded foam elements 155
9 2 3 Marking area where no welding work may be carried out 156
9 2 4 Welding in 156
10 Renewing side member reinforcement 160
10 1 Removing 162
10 2 Installing 163
10 2 1 Preparing new part 163
10 2 2 Welding in 163
11 Renewing side member reinforcement 165
11 1 Removing 166
11 2 Installing 166
11 2 1 Preparing new part 166
11 2 2 Welding in 167
12 Renewing seat cross member mounting 168
12 1 Removing 169
12 2 Installing 170
12 2 1 Preparing new part 170
12 2 2 Welding in 170
13 Renewing seat cross member mounting 171
13 1 Removing 172
13 2 Installing 173
13 2 1 Preparing new part 173
13 2 2 Welding in 173
14 Renewing seat cross member 174
14 1 Removing 175
14 2 Installing 175
14 2 1 Preparing new part 175
14 2 2 Welding in 175
53 – Body – rear 176
1 Renewing cross panel 176
1 1 Removing 177
1 2 Installing 178
1 2 1 Preparing new part 178
1 2 2 Welding in 180
1 2 3 Cutting out recesses for the tail light 182
1 2 4 Installing welding bolts 184
2 Renewing mounting plate 188
2 1 Removing 189
2 2 Installing 189
2 2 1 Preparing new part 189
2 2 2 Welding in 190
3 Renewing luggage compartment floor 192
3 1 Removing 193
3 2 Installing 195
3 2 1 Preparing new part 195
3 2 2 Moulded foam elements 196
3 2 3 Welding in 196
4 Renewing longitudinal member – partial renewal 199
4 1 Removing 200
4 2 Installing 201
4 2 1 Preparing new part 201
4 2 2 Welding in 201
5 Renewing rear longitudinal member end piece 203
5 1 Removing 204
5 2 Installing 205
5 2 1 Preparing new part 205
5 2 2 Welding in 205
6 Renewing side panel – partial replacement 207
6 1 Removing 209
6 2 Installing 211
6 2 1 Preparing new part 211
6 2 2 Moulded foam elements 212
6 2 3 Welding in 212
7 Renewing C-pillar reinforcement 216
7 1 Removing 217
7 2 Installing 218
7 2 1 Preparing new part 218
7 2 2 Welding in 218
8 Renewing outer wheel housing liner 219
8 1 Removing 221
8 2 Installing 223
8 2 1 Welding in 223
9 Renewing spare wheel well – partial renewal 226
9 1 Removing 226
9 2 Installing 227
9 2 1 Preparing new part 227
9 2 2 Welding in 228
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V