VOLKSWAGEN JETTA 2005 (06) PDF Document

Special tools and workshop equipment required include: Removal wedge -3409-, Release lever -T10039-, Removal pliers -3392-, Release tool -T10236-, Glass scraper (commercially available), Blade (commercially available), Assembly tool -3399-, Airbag adapter -VAS 6229-, Airbag adapter -VAS 6281-, Engine and gearbox support -VAS 6095-, Seat repair stand -VAS 6136-, Pop rivet pliers -VAS 5072-, Electric cutter -V.A.G 1561 A-, Cutting blade -V.A.G 1561/20-, Hand-cartridge gun -V.A.G 1628-, Release lever -T10039 /1-, Torque wrench -V.A.G 1783-, Upholstery clip pliers -V.A.G 1634-.

To remove the interior mirror with rain sensor:

Step 1. Switch off ignition.

Step 2. Using removal wedge -3409-, release fastener -1- of right cover cap -2-.

Step 3. Release left -3- and right cover caps -2- from mirror base.

Step 4. Disconnect connector -4-.

Step 5. Slide interior mirror along windscreen and then downwards out of mounting.

To install:

Step 1. Install in reverse order of removal.

The procedure for bonding on the retaining plate for the interior mirror with rain sensor involves preparing the windscreen and bonding the mirror base:

Preparing windscreen:

Step 1. All adhesive and primer residue must be removed from the ceramic pre-coating.

Step 2. Clean bonding area with cleaning solution -D 009 401 04- .

Step 3. Adhere to flash-off period of at least 10 minutes.

Step 4. Apply glass primer/paint primer -D 009 200 02- .

Step 5. Flash-off period up to bonding: minimum of 10 minutes to maximum of 1 hour.

Preparing detached or new mirror base:

Step 1. Mechanically remove adhesive remains (applies only for a mirror base which has become detached).

Step 2. Prepare adhesive surface by sanding down with wet fine emery paper (800-1200 grade) until water does not run off surface to be bonded.

Step 3. Then clean with cleaning solution -D 009 401 04- .

Bonding mirror base:

Step 1. Apply 2K polyurethane adhesive -D 180 KD2 A1- directly to sanded and cleaned mirror base bonding surface.

Step 2. Adhesive bead diameter: approx. 2.5…3 mm.

Step 3. Press mirror base into position on prepared windscreen immediately after applying adhesive to base.

Step 4. Align mirror base in position on ceramic pre-coat surface and secure with adhesive tape.

Cleaning and removing excessive adhesive:

Step 1. Carefully remove adhesive tape after 0.5…1 hour after attaching mirror base.

Step 2. Remove excessive and still soft adhesive from around mirror base using a spatula.

Step 3. Then remove remaining excessive adhesive completely using a cloth or primer applicator soaked in cleaning solution.

Installing rain sensor and mirror:

Step 1. Mirror can be fitted 2.5 hours after attaching mirror base.

To remove the interior mirror in VOLKSWAGEN JETTA 2005 vehicles with adaptive cruise control:

Step 1. Switch off ignition.

Step 2. Carefully push interior mirror -1- in direction of -arrow- and out of retaining plate.

Step 3. Press locking tabs -1- and -2- outwards and remove cap -3- from mirror.

Step 4. Disconnect connector -1-.

Step 5. Release cap -1- from fasteners along sides -arrows- and remove.

To install:

Step 1. Install in reverse order of removal.

To remove the interior mirror without rain sensor:

Step 1. Turn interior mirror -1- anti-clockwise through 90° -arrow- and release it from adhesive plate -2-.

To install:

Step 1. Install in reverse order of removal.

The materials needed are: Glass-metal adhesive kit “D 000 703 A1”.

To remove the basic version centre console (VOLKSWAGEN JETTA 2005):

For vehicles with automatic gearbox:

Step 1. Move selector lever to position “N”.

Step 2. Release selector lever cover along with handle from cover (refer to 6-speed automatic gearbox 09G; Rep. Gr. 37 ; Selector mechanism).

For vehicles with manual gearbox:

Step 1. Release boot along with gearstick knob from cover (refer to Rep. Gr. 34 ; Repairing selector mechanism).

For all vehicles:

Step 1. Switch off ignition.

Step 2. Remove hand brake lever trim (refer to Brake system; Rep. Gr. 46 ; Assembly overview – hand brake lever).

Step 3. Remove the two trim lining mats -1- from the extension -3-.

Step 4. Remove the three bolts -2- (1.5 Nm).

Step 5. Release extension -3- from fasteners.

Step 6. Pull extension -3- forwards through opening for handbrake lever.

Step 7. Release selector insulation -1- from centre console.

Step 8. Remove the two bolts -2- (1.5 Nm).

Step 9. Release storage compartment -3- from centre console and disconnect wiring harnesses (dependent on vehicle equipment).

Note: An ashtray may be installed instead of a storage compartment -3-, but the removal is identical.

Step 10. Unclip cover -1- from trim using a small screwdriver.

Step 11. Remove bolt -2- (1.5 Nm).

Step 12. Pull left footwell trim -3- out of fasteners.

Note: Removal of right footwell trim is identical.

Step 13. Unclip both side trims -4- from centre console by releasing fasteners with a removal wedge -3409- .

Step 14. Remove two bolts each -1- and -2- (1.5 Nm).

Step 15. Remove two bolts each -3- and -4- (1.5 Nm).

Step 16. Remove lining mat from rear cup holder and remove bolt -5- (1.5 Nm).

Note: When installing, bolts must be installed in sequence -1-, -2-, -3-, -4- and -5-.

Step 17. Remove centre console -1- from vehicle.

To install the basic version centre console (VOLKSWAGEN JETTA 2005):

Step 1. Install in reverse order of removal.

To remove the Highline centre console (VOLKSWAGEN JETTA 2005):

For vehicles with automatic gearbox:

Step 1. Switch off ignition.

Step 2. Move selector lever to position “N”.

Step 3. Release selector lever cover along with handle from cover (refer to 6-speed automatic gearbox 09G; Rep. Gr. 37 ; Selector mechanism).

For vehicles with manual gearbox:

Step 1. Release boot along with gearstick knob from cover (refer to Rep. Gr. 34 ; Repairing selector mechanism).

For vehicles with dual clutch gearbox:

Step 1. Switch off ignition.

Step 2. Move selector lever to position “N”.

Step 3. Release selector lever cover along with handle from cover (refer to Dual clutch gearbox 02E; Rep. Gr. 34 ; Selector mechanism).

For all vehicles:

Step 1. Switch off ignition.

Step 2. Remove hand brake lever trim (refer to Brake system; Rep. Gr. 46 ; Assembly overview – hand brake lever).

For vehicles with a CD changer:

Step 1. Remove CD changer -1- (refer to Communication; Rep. Gr. 91 ; CD changer).

Step 2. Remove lining mat -2- from storage compartment.

Step 3. Remove bolt -3- (1.5 Nm).

For vehicles with a chilled storage compartment:

Step 1. Remove lining mat -1- from storage compartment.

Step 2. Pull cover -2- out of fasteners in storage compartment.

Step 3. Remove bolt -3- (1.5 Nm).

To install the Highline centre console (VOLKSWAGEN JETTA 2005):

Step 1. Install in reverse order of removal.

To remove the mounting bracket for the basic version centre console (VOLKSWAGEN JETTA 2005):

Step 1. Switch off ignition.

Step 2. Remove centre console (Basic version (VOLKSWAGEN JETTA 2005) ⇒ page 7).

Step 3. Remove the two nuts -1- (8 Nm) and remove mounting bracket -2-.

To install:

Step 1. Install in reverse order of removal.

Safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components):

• Pyrotechnic components always contain a propellant that generates a gas during combustion. On some versions, a separate compressed gas reservoir is available to generate the gas.
• This compressed gas is stored under high pressure in a compressed gas tank.
• Ignition of the pyrotechnic components is by means of an electric/mechanical igniter.
• Testing, removing, installing and repair work may only be performed by qualified personnel.
• For airbag units, there are no exchange intervals.
• Under no circumstances should checks be carried out with a test lamp, voltmeter or ohmmeter.
• Pyrotechnic components may only be checked in installed state and with vehicle diagnosis, testing and information systems approved by the manufacturer.
• When working on pyrotechnic components and airbag control unit -J234-, the battery earth strap must be disconnected with the ignition switched on. Then cover negative terminal.
• A waiting time of 10 seconds is necessary after disconnecting the battery.
• The battery must be connected with the ignition SWITCHED ON. When doing this, there should be no-one inside the vehicle. Exception: Vehicles with battery inside passenger compartment. In this case do not stay anywhere near the effective range of the airbags and seat belts.
• Wash hands after coming into contact with triggered pyrotechnic components of restraint system.
• Pyrotechnic components must not be opened or repaired; always use new parts (risk of injury).
• Pyrotechnic components that have been dropped onto a hard surface or show signs of damage must not be installed in a vehicle.
• Before handling pyrotechnic components of the restraint system, for example before separating an electrical connection, the mechanic must electrostatically discharge him/herself. Electrostatic discharge is achieved by touching earthed metallic parts, such as the door striker plate.
• Pyrotechnic components must be installed immediately after they have been removed from their packaging.
• If work is interrupted, the pyrotechnic component must be stored back in its packaging.
• Leaving the pyrotechnic component unattended is prohibited.
• Pyrotechnic components must not come into contact with grease, cleaning solution or similar.
• Pyrotechnic components must not be subjected to temperatures above 100 °C even for short periods.

Special instructions for belt tensioners:

• Never point open end of belt tensioner at another person.
• Belt tensioner units must be handled with extreme caution during removal and installation. If handled incorrectly, there is a high risk of injury and damage in relation to the belt tensioner units.
• When connecting the belt tensioner unit, all mechanical parts (including those of the 3-point seat belt) must be properly attached. If connection of the belt tensioner unit is hindered due to tight conditions, the belt strap must be rolled up completely before connecting. In this case there is no heightened risk of safety as long as the additional safety instructions are heeded. Essentially this is aimed at battery disconnection and electrostatic discharge of the fitter prior to connection of the belt tensioner unit.
• Depending on the crash intensity, it is possible that the belt tensioner was triggered but the belt force limiter did NOT ignite. These parts are to be treated as unignited components!

Requirements for storage, transportation, and disposal of airbag, belt tensioner, and battery isolator units (pyrotechnic components):

• Storage must comply with the relevant national legislation.
• Transportation is subject to national and international regulations that govern packaging, marking, labelling and freight documentation in detail.
• Untriggered pyrotechnic components must be disposed of correctly in the original packaging in accordance with national legislation. Contact your importer if in any doubt.
• Only completely ignited pyrotechnic components may be disposed of through the commercial waste system.

To check belt webbing after an accident on the VOLKSWAGEN JETTA 2005:

Step 1. Pull belt webbing completely out of inertia reel.

Step 2. Check belt webbing for soiling, and if necessary wash with a mild soapy solution (refer to Owner’s Manual).

If either of the following illustrated damage examples (points 1 or 2) are found on accident vehicle – renew seat belt complete with belt buckle and belt height adjustment.

If damage as illustrated under points 1, 2, 3 and 4 is determined on a vehicle which has not been involved in an accident, it is sufficient to renew damaged belt only.

• Belt webbing cut, torn or chafed.
• Torn webbing loops on belt edge.
• Burn marks from cigarettes or similar.
• One edge of belt deformed or wavy.

The inertia reel has two locking functions:

The first locking function is triggered by the belt being jerked out of reel (belt extraction acceleration). Checking this function:

Step 1. Pull belt out of inertia reel with firm jerk.

If it will not lock – renew seat belt complete with buckle.

If difficulties are experienced when belt is extended or retracted, first check whether position of inertia reel has been altered.

The second locking function is triggered by a change in vehicle speed (vehicle-dependent locking function). Vehicle must be moved over a flat level surface for this. Checking this function:

Step 1. Put on seat belt.

Step 2. Accelerate vehicle to 20 km/h and then carry out emergency braking with foot brake.

If seat belt is not locked by locking mechanism during braking procedure, renew seat belt complete with buckle.

WARNING: For safety reasons, the road test should be carried out on a traffic-free stretch to ensure that other road users are not endangered.

To visually check the belt buckle:

Step 1. Inspect belt buckle for cracks and chips.

If damage is determined, renew seat belt complete with belt buckle.

Checking the belt buckle operation:

Step 1. Push latch plate into belt buckle until it engages audibly. Check whether locking mechanism is properly engaged by pulling firmly on belt webbing.

If latch plate fails even once to engage properly in belt buckle during at least 5 tests, renew seat belt complete with belt buckle.

Checking release mechanism:

Step 1. Release seat belt by pressing button on belt buckle with finger pressure.

Step 2. When belt is slack, latch plate must spring out of belt buckle on its own.

Carry out test at least 5 times. If latch plate fails even once to spring out of buckle, renew seat belt complete with belt buckle.

WARNING: Under no circumstances whatsoever may lubricant be used to eliminate noise or stiffness in belt buckle buttons.

Plastic-coated fittings show fine, parallel scoring after stress on belt system (when belt was fastened during accident) (on the other hand, wear caused by frequent belt use can be recognized by smooth wear, free of lines).

Step 1. Inspect for deformation, fracturing and cracks in plastic.

If scoring and/or damage is determined, renew seat belt complete with belt latch.

Carry out following visual and functional checks:

• Latch plate deformed (stretched)
• Height adjuster non-functional
• Anchorage points (seat, pillars, vehicle floor) distorted or thread damaged

If damage is determined on these parts, renew seat belt complete with belt buckle. If damage is determined at securing points, renew respectively.

Points to check for child seat anchors (ISOFIX) after an accident:

• Child seat anchors must be checked for damage and deformation after an accident.
• Child seat anchors welded to body must not be repaired or straightened.
• If child seat anchors bolted to body are damaged or deformed, they must be renewed.

To remove and install child seat anchorages in rear shelf:

To remove:

Step 1. Open cover cap -1-.

Step 2. Remove bolt -2- (20 Nm).

Step 3. Remove child seat anchorage -3- from rear shelf.

To install:

Step 1. Install in reverse order of removal.

General safety regulations when working on airbag:

• Observe the general safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) (refer to page 89).
• Observe the special instructions for driver and front passenger airbags (refer to page 112).

WARNING: Electrostatic discharges may result in unintentional triggering of airbag. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting the igniter and earth wires. This can be done by briefly touching the body or striker plate of the door.

Special instructions for driver and front passenger airbag:

WARNING: Removed driver and front passenger airbag units must be stored with padded side upwards.

Special instructions for curtain airbag modules:

• Place removed curtain airbag modules in packaging or on a clean, flat surface on a cover.
• Folding is acceptable as long as no damage is caused (in particular to the protective sleeve).
• To prevent any potential damage during removal and installation, curtain airbags must be handled with extreme caution.
• Until the gas generator is screwed in place, always hold it firmly by hand when handling (transportation, removal and installation, etc.).

The prerequisites for deactivating one or more airbag units have been published in the “Technical Service Handbook”.

In the “Technical Service Handbook 2”, the “Procedure ID” or the “Technical solution number” for the deactivation of airbag units is: “2000987”.

As a rule, the following components will have to be renewed following an accident where the airbag has been triggered:

• All triggered airbag units
• Supports and retainer for front passenger module if front passenger airbag was triggered.
• Coil connector with slip ring, when driver airbag has triggered.
• All seat belts with triggered belt tensioners
• In addition, the following must also be replaced if necessary (visual check): All damaged components

If airbag warning lamp -K75- does not indicate a fault, there is no requirement to replace airbag components. The seat belts should be checked separately.

To remove the driver side airbag unit (VOLKSWAGEN JETTA 2005):

Step 1. Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

Step 2. Move steering wheel to highest position.

Step 3. Extend steering wheel as far as possible into passenger compartment.

Step 4. Turn steering wheel to position in illustration.

Step 5. Insert a screwdriver into hole in back of steering wheel to stop (approx. 8 mm).

Step 6. Turn screwdriver towards driver’s door -arrow-. This action releases airbag unit fastener on right side of steering wheel.

Step 7. Turn steering wheel 180° and release airbag unit fastener on left side of steering wheel as described.

If a multifunction steering wheel is not fitted, once fasteners have been operated pull upper edge of airbag out of steering wheel.

Step 8. Turn steering wheel back through 90° to middle position.

Step 9. Remove airbag unit from steering wheel.

To install:

Step 1. Check that wiring harness -3- is routed as shown in figure.

Step 2. Insert airbag connector -2- into connector coupling. The airbag connector must audibly engage.

Step 3. Insert connector -1- into connector coupling. This procedure is only necessary on multifunction steering wheels.

Step 4. Press airbag unit into steering wheel.

Step 5. Check that airbag unit is engaged on left and right sides in steering wheel.

Step 6. Switch ignition on.

Step 7. Ensure that nobody is in vehicle.

Step 8. Reconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

To remove the knee airbag (VOLKSWAGEN JETTA 2005):

Step 1. Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

WARNING: Electrostatic discharges may result in unintentional triggering of airbag. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting the igniter and earth wires. This can be done by briefly touching the body or striker plate of the door.

Step 2. Disconnect connector from knee airbag.

Note: The connector is located on the tunnel side (in the direction of travel).

Step 3. Remove two nuts each -1- and -3- (9 Nm).

Step 4. Remove knee airbag -2- from bracket -4-.

To install:

Step 1. Install in reverse order of removal.

Step 2. Ensure airbag connector engages audibly.

Step 3. Switch ignition on.

Step 4. Ensure that nobody is in vehicle.

Step 5. Reconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

To remove the dash panel on the VOLKSWAGEN JETTA 2005:

Step 1. Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

Step 2. Remove driver airbag unit (refer to page 116).

Step 3. Remove steering wheel (refer to Running gear, axles, steering; Rep. Gr. 48 ; Removing and installing steering wheel).

Step 4. Remove turn signal switch and windscreen wiper switch (refer to Electrical system; Rep. Gr. 94 ; Steering column switch).

Step 5. Remove cover on side of dash panel (refer to page 54).

Step 6. Remove centre trim on A-pillars (refer to page 210).

Step 7. Remove upper trim on A-pillars (refer to page 209).

For Jetta 2005, Golf Variant 2007:

Step 1. Remove centre cover (refer to page 72).

Step 2. Remove centre console:

• Basic version (Jetta 2005, Golf Variant 2007) (refer to page 7).
• Highline (Jetta 2005, Golf Variant 2007) (refer to page 16).

Step 3. Remove dash panel centre vent (refer to page 43).

Step 4. Remove dash panel middle trim (refer to page 51).

Step 5. Pull dash panel out of mountings -1- in area of transition to windscreen.

Step 6. Release respective wiring harnesses (dependent on vehicle equipment) and take dash panel out of vehicle with assistance of a second mechanic.

Note: When installing dash panel, ensure that dash panel is positioned exactly in mountings -1-.

To remove the dash panel centre vents (vehicles with no Climatronic) on the VOLKSWAGEN JETTA 2005:

Step 1. Remove lining mat -1- from storage compartment.

Step 2. Remove the two bolts -2- (1.5 Nm).

Step 3. Remove storage compartment -3- from vent -4-.

To install:

Step 1. Install in reverse order of removal.

To remove the dash panel centre vents (vehicles with Climatronic) on the VOLKSWAGEN JETTA 2005:

Remove dash panel centre vents (vehicles with Climatronic) (refer to page 43).

Note: Vehicles with no Climatronic, two bolts -1- have already been removed at this point.

Step 1. Insert two wedges -3409- into lower joint of vent -arrows- and press vent upwards out of mounting in dash panel.

Step 2. Operate the respective locking devices and separate the wiring harnesses for hazard warning lights switch and front passenger airbag warning lamp.

To install:

Step 1. Install in reverse order of removal.

To remove the dash panel middle trim on the VOLKSWAGEN JETTA 2005:

Step 1. Remove dash panel centre vent (refer to page 43).

Step 2. Remove the two bolts -1- (1.5 Nm).

Step 3. Using removal wedge -3409- prise trim out of fasteners in dash panel (insert wedge close to fastener).

To install:

Step 1. Install in reverse order of removal.

To remove the dash panel decorative trims on the VOLKSWAGEN JETTA 2005 (driver side):

Step 1. Prise trims -1- and -2- out of dash panel on driver side using removal wedge -3409- .

To remove the dash panel decorative trims on the VOLKSWAGEN JETTA 2005 (passenger side):

Step 1. Prise trim -3- out of fasteners on front passenger side using removal wedge -3409- .

To install:

Step 1. Install in reverse order of removal.

To remove the centre cover (VOLKSWAGEN JETTA 2005):

Step 1. Prise cover -1- out of fasteners using removal wedge -3409- .

To install:

Step 1. Install in reverse order of removal.

To remove the sill panel mouldings on the VOLKSWAGEN JETTA 2005 (for the left vehicle side, follow same instructions for the right side as appropriate):

Step 1. Remove side padding (refer to page 288 for with no rear side airbags or page 287 for with rear side airbags).

Step 2. Remove wheel housing liner (refer to page 78 for Saloon or page 79 for Variant).

Step 3. Pull sill panel moulding out of front area of sill and beading of door seal.

Step 4. Release guide -1- from lower B-pillar trim.

Step 5. Pull sill panel moulding out of rear area of sill and beading of door seal.

Step 6. Release guide -2- from lower B-pillar trim.

Step 7. Open tab -3- and guide seat belt out through.

To install:

Step 1. Install in reverse order of removal.

Note: Before installing, check fasteners for damage and renew if necessary.

To remove and install the wheel housing liner (saloon) on the VOLKSWAGEN JETTA 2005 (described for the left vehicle side, follow same instructions for the right side as appropriate):

To remove:

Step 1. Remove bench seat (refer to page 284).

Step 2. Remove side padding (refer to page 288 for with no rear side airbags or page 287 for with rear side airbags).

Step 3. Remove the two bolts -1- (1.5 Nm).

Step 4. Release clips -2- from body flange.

Step 5. Pull trim -3- out from beading of door seal -4-.

Step 6. Pull moulding out of fasteners in sill panel moulding -5-.

Step 7. Pull trim out forwards under C-pillar trim.

To install:

Step 1. Install in reverse order of removal.

Note: Before installing, check fasteners for damage and renew if necessary.

To remove the roof grab handles on the VOLKSWAGEN JETTA 2005 (figure shows front right grab handle, removal and installation of the remaining grab handles is identical):

To remove:

Step 1. Fold down grab handle and open the two cover caps -1- and -2- using a small screwdriver.

Step 2. Remove the two bolts -3- (2 Nm) and remove grab handle.

To install:

Step 1. Install in reverse order of removal.

To remove and install the roof grab handle bracket on the VOLKSWAGEN JETTA 2005 (figure shows front right grab handle bracket, removal and installation of the remaining grab handle brackets is identical):

To remove:

Step 1. Lower moulded headliner.

Step 2. Remove the two bolts -1- (2 Nm) and remove the bracket -2-.

To install:

Step 1. Install in reverse order of removal.

To remove the net partition on the VOLKSWAGEN JETTA 2005:

Step 1. Open rear right door and fold rear seat backrests forward.

Step 2. Pull net partition -1- outwards in direction of -arrow- and out of mounting -2- in rear right seat backrest.

To install:

Step 1. Install in reverse order of removal.

For net partition mountings on the VOLKSWAGEN JETTA 2005:

Bolt -2- requires 8 Nm torque.

Bolt -8- requires 8 Nm torque.

For removing and installing the net partition (refer to page 84).

For removing and installing luggage compartment side trim (Variant) (refer to page 231).

To remove and install the net partition bracket on vehicles with no panorama sliding roof on the VOLKSWAGEN JETTA 2005:

Net partition (refer to page 84).

Bolt -2- requires 2 Nm torque.

Moulded headlining (refer to page 245 for removing and installing).

Rear net partition bracket -6-.

Bolt -7- requires 4.5 Nm torque.

Front net partition bracket -8-.

To remove and install the net partition bracket on vehicles with panorama sliding roof on the VOLKSWAGEN JETTA 2005:

Net partition (refer to page 84).

Bolt -2- requires 2 Nm torque.

Moulded headlining (refer to page 245 for removing and installing).

Rear net partition bracket -6-.

Bolt -7- requires 4.5 Nm torque.

Front net partition bracket -8-.

To remove the front seat belts on the VOLKSWAGEN JETTA 2005 (removal and installation described for the left vehicle side, follow same instructions for the right side as appropriate):

WARNING: Observe the general safety regulations when working on airbag, belt tensioner and battery isolator units (pyrotechnic components) (refer to page 89) and follow the special instructions for belt tensioners (refer to page 90).

Step 1. Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

Step 2. Remove upper trim for B-pillar (refer to page 213).

Step 3. Remove lower B-pillar trim (refer to page 215).

Step 4. Remove bolt -1- (40 Nm) and remove belt end anchor -2- from body.

Caution: Bolt -1- may be microencapsulated. For this reason, the bolt has to be heated with a hot air blower before it can be loosened. The neighbouring seat belt must be protected against the heat with a damp cloth when doing this.

Note: If the bolt is microencapsulated, it must be renewed if loosened. Before a new bolt is installed, the thread of the nut must be cleaned and chased as necessary.

Step 5. Remove bolt -3- (40 Nm) and remove belt inertia reel -4- from B-pillar.

WARNING: Electrostatic discharges may result in unintentional triggering of belt tensioner. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting the igniter and earth wires. This can be done by briefly touching the body or striker plate of the door.

Step 6. Disconnect wiring harness -5-.

Step 7. Remove bolts -6- (4.5 Nm) and remove belt guide -7-.

Step 8. Remove bolt -8- (40 Nm) and remove belt guide fitting -9- from belt height adjuster.

To install:

Step 1. Install in reverse order of removal.

Step 2. Reconnect vehicle battery (refer to Rep. Gr. 27).

To remove and install the front belt height adjuster on the VOLKSWAGEN JETTA 2005 (removal and installation described for the left vehicle side, follow same instructions for the right side as appropriate):

To remove:

Step 1. Remove upper trim for B-pillar (refer to page 213).

Note: There is no need to remove the belt end anchor or anchor rail from front seat belt.

Step 2. Remove bolt -1- (40 Nm) and remove belt guide fitting -2- from belt height adjuster.

Step 3. Remove bolt -3- (20 Nm) and remove belt height adjuster -4- from mountings in support bracket.

To install:

Step 1. Install in reverse order of removal.

To remove and install the front belt buckle on the VOLKSWAGEN JETTA 2005 (removal and installation described for left side of vehicle, follow same instructions for removal and installation of belt buckle on right side as appropriate):

To remove:

Step 1. Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Step 2. Remove front seat (refer to page 251).

Step 3. Secure seat to seat repair stand -VAS 6136- .

Step 4. Move seat to rearmost position.

Step 5. Disconnect belt buckle wiring harness from seat frame.

Step 6. Remove cover cap from seat rail.

Step 7. Remove bolt -1- (20 Nm).

Note: The bolt is microencapsulated and must be renewed each time it is loosened. Before a new bolt is installed, the thread of the nut must be cleaned and chased as necessary.

Step 8. Pull belt buckle -2- out of mounting in seat rail -arrow-.

To install:

Step 1. Install in reverse order of removal.

To remove and install the rear outer seat belts (saloon) on the VOLKSWAGEN JETTA 2005 (removal and installation described for the left vehicle side, follow same instructions for the right side as appropriate):

To remove:

Step 1. Remove bench seat (refer to page 284).

Step 2. Remove side padding (refer to page 288 for with no rear side airbags or page 287 for with rear side airbags).

Step 3. Remove C-pillar trim (refer to page 217).

Step 4. Remove rear shelf (refer to page 221).

Step 5. Remove bolt -1- (40 Nm) and remove belt guide fitting -2- from body.

Step 6. Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

WARNING: Electrostatic discharges may result in unintentional triggering of airbag. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting wiring. This can be done by briefly touching the body or striker plate of the door.

Step 7. Disconnect wiring harness -3-.

Step 8. Remove bolt -4- (40 Nm) and remove belt inertia reel -5- from body -arrow-.

To install:

Step 1. Install in reverse order of removal.

To remove and install the rear outer seat belts (Variant) on the VOLKSWAGEN JETTA 2005 (removal and installation described for right side of vehicle, follow same instructions for left side as appropriate):

To remove:

Step 1. Remove side padding (refer to page 288 for with no rear side airbags or page 287 for with rear side airbags).

Step 2. Remove luggage compartment side trim (refer to page 231).

Step 3. Remove bolt -1- (40 Nm) and remove belt guide fitting -2- from body.

Step 4. Vehicles with belt tensioner: Disconnect vehicle battery (refer to Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting battery).

WARNING: Electrostatic discharges may result in unintentional triggering of airbag. Therefore, the mechanic must electrostatically discharge him/herself before disconnecting wiring. This can be done by briefly touching the body or striker plate of the door.

Step 5. Vehicles with belt tensioner: Disconnect wiring harness connector -7-.

Step 6. All vehicles: Unbolt bolt -6- (40 Nm) and release belt inertia reel -5- from mounting.

Step 7. To remove belt guide -3-, unbolt bolts -4- (6 Nm) and take belt guide off upwards.

To install:

Step 1. Install in reverse order of removal.

To remove and install the rear centre 3-point seat belt on the VOLKSWAGEN JETTA 2005:

To remove (Saloon):

Step 1. Remove bench seat (refer to page 284).

Step 2. Remove backrest (refer to page 285).

Step 3. Remove cover and padding from seat backrest (refer to page 302).

To remove (Variant):

Step 1. Fold bench seat forwards.

Step 2. Remove backrest (refer to page 285).

Step 3. Remove cover and padding from seat backrest (refer to page 305).

For all vehicles:

Step 1. Remove cover and padding from seat backrest (refer to page 305).

Step 2. Remove bolt -1- (40 Nm) and remove belt buckle -2- from body.

Step 3. Remove hexagon nut -3- (40 Nm) and remove belt inertia reel -4- from console -5-.

Step 4. Guide belt buckle -2- through console -5-.

To install:

Step 1. Install in reverse order of removal.

To remove the middle rear seat lap belt on the VOLKSWAGEN JETTA 2005:

To remove:

Step 1. Remove bench seat (refer to page 298).

Step 2. Remove backrest (refer to page 285 for Saloon or page 305 for Variant).

Step 3. Remove bolt -1- (40 Nm) and remove lap belt -2- from body.

To install:

Step 1. Install in reverse order of removal.

To remove the rear double belt buckle on the VOLKSWAGEN JETTA 2005:

For Saloon:

Step 1. Remove bench seat (refer to page 284).

For Variant:

Step 1. Fold bench seat forwards.

For all vehicles:

Step 1. Remove backrest (refer to page 285).

Step 2. Remove bolt -1- (40 Nm) and remove double belt buckle -2- from body.

To install:

Step 1. Install in reverse order of removal.

To remove and install the front seat cushion cover and padding on the VOLKSWAGEN JETTA 2005 (removal and installation described for the left seat, apply same instructions for removal and installation of right seat components as appropriate):

To remove:

Step 1. Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Step 2. Remove front seat (refer to page 251).

Step 3. Secure seat to seat repair stand -VAS 6136- .

Step 4. Remove right trim on seat (Seat with no folding backrest ⇒ page 257; Seat with folding backrest ⇒ page 259).

For vehicles with manually adjustable seat:

Step 1. Remove left trim on seat (Seat with no folding backrest ⇒ page 255; Seat with folding backrest ⇒ page 258).

Step 2. Remove bar and operating lever for front seat (⇒ page 265).

For vehicles with electrically adjustable backrest on front passenger seat (USA):

Step 1. Remove right trim on seat (⇒ page 260).

Step 2. Remove bar and operating lever for electrically adjustable backrest on front seat (⇒ page 266).

For vehicles with electrically adjustable seat:

Step 1. Remove left trim on electrically adjustable seat (⇒ page 261).

For all vehicles:

Step 1. Remove front seat backrest (⇒ page 268).

Step 2. Secure backrest to seat repair stand -VAS 6136- .

Step 3. Operate button in head restraint guide and pull head restraint -2- out of backrest.

Step 4. Remove head restraint guides -1- and -3- (refer to page 268).

For vehicles with manually operated lumbar support adjustment only:

Step 1. Using removal pliers -3392- , remove knob -4- for lumbar support adjustment.

For all vehicles:

Step 1. Unhook profile -5- on both sides of backrest.

Step 2. Release profile -6- from mounting -7-.

Step 3. Using a small screwdriver, unclip cover profile -1- from mountings -2- in padding.

Step 4. If vehicle is equipped with seat heating, disconnect wiring harness -3- from seat frame.

For vehicles with seat occupied recognition:

Step 1. Remove cover -4- from padding -5- and seat frame -6-.

Step 2. Remove front seat cushion padding -5- with components for seat occupied recognition (refer to page 150).

Caution: The front seat cushion padding, the mat for the seat occupied recognition, the pressure hose, the pressure sensor for seat occupied recognition -G452- and the seat occupied recognition control unit -J706- may not be disconnected.

For vehicles with no seat occupied recognition:

Step 1. Remove cover -4- and padding -5- from seat frame -6-.

To install:

Step 1. Install in reverse order of removal.

Upholstery clip pliers -V.A.G. 1634- are required when installing new padding clips.

To remove and install the front seat backrest cover and padding on the VOLKSWAGEN JETTA 2005 (removal and installation described for the left seat, apply same instructions for removal and installation of right seat components as appropriate):

To remove:

Step 1. Attach seat repair stand -VAS 6136- to engine and gearbox support -VAS 6095- .

Step 2. Remove front seat (refer to page 251).

Step 3. Secure seat to seat repair stand -VAS 6136- .

Step 4. Remove right trim on seat (Seat with no folding backrest ⇒ page 257; Seat with folding backrest ⇒ page 259).

For vehicles with manually adjustable seat:

Step 1. Remove left trim on seat (Seat with no folding backrest ⇒ page 255; Seat with folding backrest ⇒ page 258).

Step 2. Remove front seat backrest (⇒ page 268).

Step 3. Secure backrest to seat repair stand -VAS 6136- .

Step 4. Operate button in head restraint guide and pull head restraint -2- out of backrest.

Step 5. Remove head restraint guides -1- and -3- (refer to page 268).

For vehicles with manually operated lumbar support adjustment only:

Step 1. Using removal pliers -3392- , remove knob -4- for lumbar support adjustment.

For all vehicles:

Step 1. Unhook profile -5- on both sides of backrest.

Step 2. Release profile -6- from mounting -7-.

Step 3. Unhook left and right tensioning wire -1- from backrest frame.

Step 4. Release left and right profiles -2- from mountings -3-.

Step 5. Pull backrest cover upwards.

Step 6. Using a small screwdriver, unclip backrest cover profile -4- from mountings -5- in padding.

To install:

Step 1. Install in reverse order of removal.

To remove the bench seat cover and padding (saloon) on the VOLKSWAGEN JETTA 2005:

Step 1. Remove bench seat (refer to page 284).

Step 2. Unhook all cover profiles -arrows- from seat frame on underside of bench seat.

Step 3. Release Velcro strips -1- in area of belt buckles.

Step 4. Roll up cover on sides.

Step 5. Using a small screwdriver, lever side webs out of fasteners -1- and pull out clamping strips -2-.

Step 6. Detach cover -3- and padding -4- from seat frame -5-.

To install:

Step 1. Install in reverse order of removal.

To remove and install the bench seat cover and padding (Variant) on the VOLKSWAGEN JETTA 2005 (procedure described for the right bench seat, apply same procedures for the left side and other equipment versions as appropriate):

To remove:

Step 1. Remove bench seat (refer to page 284).

Step 2. Unhook profiles -3- from cover -2-, in direction of -arrow-, all round on underside of seat frame -1-.

Step 3. Cut through all padding clips -arrows- all-round underside of bench seat using suitable cutting pliers.

Step 4. Roll up cover -4- at sides.

Step 5. Cut through padding clips -5- using suitable cutting pliers and pull cover -4- from padding -3-.

Step 6. Then take padding -4- and cover -2- off seat frame -1-.

To install:

Step 1. Install in reverse order of removal.

To remove the through-loading unit with centre armrest on the VOLKSWAGEN JETTA 2005:

Step 1. Unclip padded piece -1- from under centre armrest.

Step 2. Open through-loading unit -2- and remove the two bolts -3- (9 Nm).

To install:

Step 1. Install in reverse order of removal.

To adjust the through-loading unit with centre armrest:

Step 1. Clipsen Sie die Polstereinlage -1- unterhalb der Mittelarmlehne heraus und lösen Sie die Schrauben -2-

Note: Es ist nicht notwendig die Schrauben -2- herauszudrehen.

Step 2. Öffnen Sie die Mittelarmlehne -3- .

Step 3. Öffnen und Schließen Sie mit Druck zwei mal die Durchladeeinheit -4-.

Step 4. Schließen Sie die Mittelarmlehne.

Step 5. Ziehen Sie die Schrauben -2- fest.

Step 6. Clipsen Sie die Polstereinlage -1-.

To remove the centre armrest on the VOLKSWAGEN JETTA 2005:

Step 1. Fold open centre armrest -1- to 2/3 position.

Step 2. Remove cover -2-.

Step 3. Remove bolts -3- (12 Nm).

Step 4. Remove centre armrest -1- from through-loading unit -4-.

To install:

Step 1. Install in reverse order of removal.