VOLKSWAGEN JETTA 2005 (07) PDF Document

The special tools and workshop equipment required for the Lock carrier repair on the VOLKSWAGEN JETTA 2005 are:

• Guide pins -T10093-
• Torque wrench -V.A.G 1331-
• Torque wrench -V.A.G 1332-

The specified torque for bolt -2- in the Lock carrier assembly overview for the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolt -3- in the Lock carrier assembly overview for the VOLKSWAGEN JETTA 2005 is 60 Nm.

The steps involved in moving the lock carrier to the service position for the VOLKSWAGEN JETTA 2005 are:

• Remove front bumper cover (refer to page 223).
• Remove air duct from lock carrier -1- (refer to Repair Group 24; Repairing injection system).
• Unhook Bowden cable from coupling for bonnet release (refer to page 24).
• If the vehicle has a charge air cooler, disconnect pressure hoses (refer to page 4).
• Unscrew horn -4- with bracket on the right side of the longitudinal member (refer to Electrical system; Repair Group 96; Horn).
• Pull connector off high-pressure sender -G65- (refer to Heating, air conditioning system; Repair Group 87).
• Remove bolts -3- from the left and right longitudinal members.
• Attach special tool guide pins -T10093- to the left and right longitudinal members.
• Remove bolts -2- on the left and right from the upper part of the lock carrier -1-.
• The lock carrier -1- can be pulled forwards on the guide pins -T10093-.

To move the lock carrier from the service position for the VOLKSWAGEN JETTA 2005, install in reverse order of removal, and align the lock carrier on the longitudinal members and between the wings (refer to Body Repairs; Repair Group 00; Body dimensions).

When removing the lock carrier with add-on parts for the VOLKSWAGEN JETTA 2005, it should be noted that the lock carrier is a safety-relevant component and must not be repaired. If damaged, the lock carrier must be renewed.

The special tools and workshop equipment required for the Wing repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1783-

The specified torque for bolt -2- in the Assembly overview – front wing for the VOLKSWAGEN JETTA 2005 is 6 Nm.

The steps to remove the wing for the VOLKSWAGEN JETTA 2005 are:

• Remove front bumper cover (refer to page 223).
• Remove front and rear parts of wheel housing liner (refer to page 321).
• Remove guide (refer to Item 4 on page 227).
• Loosen hexagon nut -6- and remove bolts -2-.
• Pull out foam element -3- between wing and longitudinal member and remove wing -1-.

The special tools and workshop equipment required for the Noise insulation repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1783-

The specified torque for bolt -2- in the Assembly overview – noise insulation for the VOLKSWAGEN JETTA 2005 is 2 Nm.

The special tools and workshop equipment required for the Underbody cladding repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1783-

The specified torque for hexagon nut -2- in the Assembly overview – underbody cladding for the VOLKSWAGEN JETTA 2005 is 1.5 Nm.

The specified torque for bolt -4- in the Assembly overview – underbody cladding for the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolt -1- in the Assembly overview – rear underbody cladding for the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for hexagon nut -3- in the Assembly overview – rear underbody cladding for the VOLKSWAGEN JETTA 2005 is 1.5 Nm.

The special tools and workshop equipment required for the Plenum chamber bulkhead repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1783-

The specified torque for hexagon nut -2- is 8 Nm, and the specified torque for bolt -4- is 8 Nm in the Assembly overview – plenum chamber bulkhead for the VOLKSWAGEN JETTA 2005.

The special tools and workshop equipment required for the Bonnet repair on the VOLKSWAGEN JETTA 2005 are:

• Torque wrench -V.A.G 1331-
• Removal lever -80-200-

The removal instructions for the bonnet on the VOLKSWAGEN JETTA 2005 are:

• Remove left and right washer jets (refer to Electrical system; Repair Group 92; Windscreen washer system).
• Unclip line -2- from bonnet hinge -3- and bonnet -5-.
• Pull line -2- out through aperture in bonnet -5-.
• Loosen hexagon nuts -1- on left and right (do not remove).
• Disconnect gas strut -4- from bonnet -5- (refer to page 19).
• Now remove hexagon nuts -1- and lift bonnet -5- out of bonnet hinges -3-.

The specified torque for the bonnet hexagon nut on the VOLKSWAGEN JETTA 2005 during installation is 22 Nm.

The specified torque for ball-head pins -3- and -4- when removing the gas strut for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The procedure for releasing gas from a gas strut on the VOLKSWAGEN JETTA 2005 is to clamp the gas strut in a vice in the area marked -x- = 50 mm (2 in) and saw through the cylinder of the gas strut within the first third of the cylinder’s overall length using the piston rod end of the cylinder as a reference point.

When sawing, wear eye protection, cover the area of the saw cut with a cloth, and dispose of oil and cloth via existing disposal channels.

The specified torque for bolts -2- when installing the wing bracket for the VOLKSWAGEN JETTA 2005 is 6 Nm.

The special tools and workshop equipment required for the Rear lid (saloon) repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1331-

The specified torque for hexagon nut -6- in the Assembly overview – rear lid (saloon) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The specified torque for bolt -9- in the Assembly overview – rear lid (saloon) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The steps to remove the rear lid (saloon) for the VOLKSWAGEN JETTA 2005 are:

• Open rear lid.
• Remove rear lid trim (refer to General body repairs, interior; Repair Group 70; Rear lid trim).
• Disconnect connectors -1- and pull wiring -2- with rubber grommet out of lid.
• Loosen hexagon nuts -3- on left and right lid hinges (do not unbolt completely). Further dismantling requires the assistance of a second mechanic.
• Detach gas struts -4- on left and right of rear lid (refer to page 30).
• Now, and only now, unbolt bolts -3- and remove rear lid.

The specified torque for the rear lid hexagon nut when installing the rear lid (saloon) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The important notes for adjusting the rear lid seal on the VOLKSWAGEN JETTA 2005 are:

• During production, a sealant is applied to the rear lid seals, the seal is then placed on the body flange and rolled on.
• When seals are removed, the sealant will spread to the inside of the seal and the flanks will be bent out slightly. If the seal is then refitted, a leak-free tight seal is not guaranteed.
• Therefore each seal which is removed completely should be replaced by a so-called “tap-on” seal.
• If a seal has been partially removed, squeeze sides of seal together before refitting.

The special tools and workshop equipment required for the Front doors, door components, central locking repair on the VOLKSWAGEN JETTA 2005 are:

• Socket -T10072-
• Assembly tool -T10118-
• Door alignment tool -3320- with -3320/1- , -3320/2- and -3320/3-
• Roller for door insulation foil -3356-
• Torque wrench -V.A.G 1331-
• Setting gauge -3371-

The materials required for the Front door repair on the VOLKSWAGEN JETTA 2005 are:

• 1K or 2K glass adhesive -DH 009 100 01- or -DH 004 600 A2-
• Glass primer/paint primer -D 009 200 02-
• Cleaning solution -D 009 401 04-
• Primer applicator -D 009 500 25-

Observe curing period (refer to page 82). Heat according to manufacturer’s instructions, using cartridge heater -V.A.G 1939 A-. Materials are stored in box -D 004 700- .

The specified torque for bolt -3- in the Assembly overview – door assembly for the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for bolt -5- in the Assembly overview – door assembly for the VOLKSWAGEN JETTA 2005 is 14 Nm.

The specified torque for bolt -8- in the Assembly overview – door inner part for the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for bolts -4-, -5- and -11- when installing the door on the right side for the VOLKSWAGEN JETTA 2005 is 20 Nm + 1/4 turn further (90°). Bolts -4-, -5- and -11- must always be renewed.

The specified torque for bolts -4- when removing the bonnet lock for the VOLKSWAGEN JETTA 2005 is 12 Nm.

The specified torque for bolts -1- when adjusting the bonnet for the VOLKSWAGEN JETTA 2005 is 12 Nm.

The specified torque for ball-head pins -3- and -4- when removing the gas strut for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The special tools and workshop equipment required for the Rear door (saloon) repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1331-

The specified torque for hexagon nut -6- in the Assembly overview – rear lid (saloon) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The specified torque for bolt -9- in the Assembly overview – rear lid (saloon) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The steps to remove the rear lid (saloon) for the VOLKSWAGEN JETTA 2005 are:

• Open rear lid.
• Remove rear lid trim (refer to General body repairs, interior; Repair Group 70; Rear lid trim).
• Disconnect connectors -1- and pull wiring -2- with rubber grommet out of lid.
• Loosen hexagon nuts -3- on left and right lid hinges (do not unbolt completely). Further dismantling requires the assistance of a second mechanic.
• Detach gas struts -4- on left and right of rear lid (refer to page 30).
• Now, and only now, unbolt bolts -3- and remove rear lid.

The specified torque for the rear lid hexagon nut when installing the rear lid (saloon) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The steps to remove the gas strut for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 are:

• Open rear lid and support it.
• Position a small screwdriver beneath spring clip -2-.
• Raise spring clip -2- until it can be moved over ball socket in direction of -arrow-.
• Pull gas strut -1- off ball-head pins -3- and -4-.
• Slide spring clip -2- back immediately after removing gas strut -1-.

The specified torque for ball sockets -3- and -4- when releasing gas from the gas strut for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 20 Nm.

The specified torque for lid hinge bolts -1- when installing the lid hinge for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 22 Nm.

The specified torque for bolts -1- when installing the striker pin for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 23 Nm.

The requirements for rear lid adjustment on the VOLKSWAGEN JETTA 2005 are:

• Vehicle must be standing on the ground to perform the basic adjustment of the rear lid.
• The rear lid lock is bolted directly to the rear lid. It does not have elongated holes, so it cannot be adjusted.
• The stop buffers -3- on the left and right are not a means of adjustment. Their purpose is to stabilise and dampen the rear lid -1-.
• The rear lid is adjusted correctly if the gaps/shut lines are even all around, the door is not too deep or does not stand proud and all contours align when the rear lid is closed.
• The rear lid must engage in the striker pin -4- without excessive force.

The steps for adjusting the adjustment buffer for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 are:

• Loosen grub screw -1- until it is visible in rubber buffer.
• Now pull detent slide out of adjustment buffer.
• Adjust detent slide to dimension -a- = 12.5 mm.
• Close rear lid to detent position with light pressure at centre of lid.
• Open rear lid again.
• Screw in adjustment buffer clamping screw -1- to a depth of dimension -a – = 25 mm.
• Check setting.

The specified torque for hexagon nuts when installing the lid lock for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for hexagon nuts when installing the lock cylinder for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for hexagon nuts when installing the handle trim for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for hexagon nuts when installing the lid lock for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The special tools and workshop equipment required for the Rear door (saloon) repair on the VOLKSWAGEN JETTA 2005 are:

• Socket -T10072-
• Assembly tool -T10118-
• Door alignment tool -3320- with -3320/1- , -3320/2- and -3320/3-
• Roller for door insulation foil -3356-
• Torque wrench -V.A.G 1331-
• Setting gauge -3371-

The specified torque for bolts -3- when installing the rear door (saloon) for the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for bolts -2- when installing the rear door (saloon) for the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for bolts -1- when adjusting the striker pin for the rear door (saloon) on the VOLKSWAGEN JETTA 2005 is 20 Nm.

The specified torque for bolt -3- when adjusting the adjustment buffer for the rear door (saloon) on the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for bolt -5- when adjusting the adjustment buffer for the rear door (saloon) on the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for nuts when installing the release button for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for hexagon nuts when installing the lid lock for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolts -2- when installing the lid lock for the rear lid (saloon) on the VOLKSWAGEN JETTA 2005 is 24 Nm.

The special tools and workshop equipment required for the Rear lid (Variant) repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench 5…50 Nm -V.A.G 1331-

The bolts -3- on hinge -2- are loosened but not removed when removing the rear lid (Variant) for the VOLKSWAGEN JETTA 2005.

The specified torque for rear lid hexagon nut when installing the rear lid (Variant) for the VOLKSWAGEN JETTA 2005 is 22 Nm.

The steps for releasing gas from the gas strut for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 are:

• Clamp gas strut in vice in area marked -x- = 50 mm.
• Saw through cylinder of gas strut within first third of cylinder’s overall length using piston rod end of cylinder as reference point.

When releasing gas, wear eye protection when sawing, cover the area of saw cut with a cloth, and dispose of oil and cloth via existing disposal channels.

The specified torque for nuts -2- when installing the rear lid hinge for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 24 Nm.

The specified torque for bolts -1- when adjusting the striker pin for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 23 Nm.

The specified torque for bolt -3- when adjusting the adjustment buffer for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for bolt -5- when adjusting the adjustment buffer for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 10 Nm.

The specified torque for nuts when installing the release button for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolts -2- when installing the lid lock for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 24 Nm.

The specified torque for bolt -4- when installing the registration plate carrier for the rear lid (Variant) on the VOLKSWAGEN JETTA 2005 is 4 Nm.

The specified torque for bolt -4- when removing and installing the tank flap unit (saloon) for the VOLKSWAGEN JETTA 2005 is 1.5 Nm.

The specified torque for securing bolts -10- when removing and installing the tank filler flap locking motor -V155- for the tank flap unit (saloon) on the VOLKSWAGEN JETTA 2005 is 1.5 Nm.

The specified torque for bolt -4- when removing and installing the tank flap unit (Variant) for the VOLKSWAGEN JETTA 2005 is 1.5 Nm.

The special tools and workshop equipment required for the Sliding/tilting sunroof with glass panel (Meritor) repair on the VOLKSWAGEN JETTA 2005 are:

• Roller for door insulation foil -3356-
• Front end hook -3370-
• Torque wrench -V.A.G 1783-
• Removal wedge -3409-

The procedure for establishing reference points of the sliding sunroof motor when the ignition is switched on for the Sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN JETTA 2005 is:

• Rotary switch must be in “Sliding sunroof closed” position.
• Pull rotary switch -1- downwards and hold during whole process to establish reference points (approx. 20 s) in this position.
• When establishing reference points, glass panel first closes and then moves approx. 200 mm towards the rear.
• After glass panel is closed again, establishment of reference points is finished and rotary switch must be released.

The specified torque for bolts -1- when adjusting the height of the sliding/tilting sunroof glass panel for the VOLKSWAGEN JETTA 2005 is 5 Nm.

The specified torque for bolts -3- when adjusting the height of the rear panel for the Sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN JETTA 2005 is 5 Nm.

The special tools and workshop equipment required for the Panorama sliding sunroof (Arvin-Meritor) repair on the VOLKSWAGEN JETTA 2005 are:

• Roller for door insulation foil -3356-
• Torque wrench -V.A.G 1783-
• Adhesive strip remover -VAS 6349-

The specified torque for bolts -4- when removing and installing the front glass panel for the Panorama sliding sunroof (Arvin-Meritor) on the VOLKSWAGEN JETTA 2005 is not explicitly stated, but bolts -2- are tightened to 5 Nm after adjusting the front glass panel height.

The specified torque for bolts -2- when removing and installing the rear glass panel for the Panorama sliding sunroof (Arvin-Meritor) on the VOLKSWAGEN JETTA 2005 is 5 Nm.

The specified torque for bolts -12- when assembling the carrier unit for the Sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolts -2- when installing the carrier unit for the Sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for screws when installing the sliding/tilting sunroof glass panel drive for the Sliding/tilting sunroof with glass panel (Meritor) on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

For cleaning water drain hoses on the Sliding/tilting sunroof with glass panel (Meritor) for the VOLKSWAGEN JETTA 2005, a locally manufactured tool made from a speedometer inner cable, approximately 2300 mm long, is recommended.

The special tools and workshop equipment required for the Front bumper repair on the VOLKSWAGEN JETTA 2005 are:

• Torque wrench -V.A.G 1783-
• Torque wrench -V.A.G 1332-

The specified torque for bolt -1- in the Assembly overview – bumper cover for the Front bumper on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolt -2- in the Assembly overview – bumper cover for the Front bumper on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

The specified torque for bolt -4- in the Assembly overview – bumper cover for the Front bumper on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolt -5- in the Assembly overview – bumper cover for the Front bumper on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolt -6- in the Assembly overview – bumper cover for the Front bumper on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

The specified torque for bolts -2- when installing the front bumper cover for the Front bumper, Cup Edition on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolts -3- when installing the front bumper cover for the Front bumper, Cup Edition on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolts -4- when installing the front bumper cover for the Front bumper, Cup Edition on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

The specified torque for bolts -5- when installing the front bumper cover for the Front bumper, Cup Edition on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolts -6- when installing the front bumper cover for the Front bumper, Cup Edition on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

The specified torque for bumper carrier bolts -2- in the Assembly overview – front bumper carrier for the VOLKSWAGEN JETTA 2005 is 60 Nm.

The specified torque for bolts -3- in the Assembly overview – front bumper carrier for the VOLKSWAGEN JETTA 2005 is 8 Nm.

The special tools and workshop equipment required for the Rear bumper (saloon) repair on the VOLKSWAGEN JETTA 2005 are:

• Torque wrench -V.A.G 1783-
• Torque wrench -V.A.G 1331-

The specified torque for bolt -1- in the Assembly overview – bumper cover for the Rear bumper (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolt -2- in the Assembly overview – bumper cover for the Rear bumper (saloon) on the VOLKSWAGEN JETTA 2005 is 5 Nm.

The specified torque for bolt -4- in the Assembly overview – bumper cover for the Rear bumper (saloon) on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolt -5- in the Assembly overview – bumper cover for the Rear bumper (saloon) on the VOLKSWAGEN JETTA 2005 is 5 Nm.

The specified torque for bolt -7- in the Assembly overview – bumper cover for the Rear bumper (saloon) on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolts -4- when removing the rear bumper cover for the Rear bumper, saloon, Cup Edition on the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque settings for bolts -1, 2, 4, 5 and 7- when installing the rear bumper cover for the Rear bumper, saloon, Cup Edition on the VOLKSWAGEN JETTA 2005 are found on page 243.

The specified torque for bolts -2- in the Assembly overview – rear bumper carrier for the Rear bumper (Variant) on the VOLKSWAGEN JETTA 2005 is 20 Nm.

The special tools and workshop equipment required for the Rear bumper (Variant) repair on the VOLKSWAGEN JETTA 2005 are:

• Torque wrench -V.A.G 1783-
• Torque wrench -V.A.G 1331-

The specified torque for bolt -1- when installing the towing bracket for the Rear bumper (Variant) on the VOLKSWAGEN JETTA 2005 is 20 Nm.

The specified torque for bolts -4- when installing the towing bracket for the Rear bumper (Variant) on the VOLKSWAGEN JETTA 2005 is 50 Nm + turn 90° + 30° further.

The special tools and workshop equipment required for the Flush bonded windows repair on the VOLKSWAGEN JETTA 2005 are:

• Removal kit for flush bonded windows -V.A.G 1474 A-
• Suction lifter -V.A.G 1344-
• Cutting tool -V.A.G 1351-
• Windscreen removal kit -V.A.G 1755-
• Cartridge gun -V.A.G 1628-
• Cartridge heater -V.A.G 1939 A-
• Electric cutter -V.A.G 1561 A-
• Cutting blade -V.A.G 1561/2-
• Scraping blade -V.A.G 1561/8-
• Cutter (offset) -V.A.G 1561/10-
• Cutting blade -V.A.G 1561/19-
• Double cartridge gun -VAS 5237-
• Removal wedge -T10039/1-

The materials required for the Flush bonded windows repair on the VOLKSWAGEN JETTA 2005 are:

• 2K glass adhesive -DA 004 600 A2-
• 1K glass adhesive -DH 009 100 03-
• Activator -D 181 801 A1-
• Glass primer/paint primer -D 009 200 02-
• Cleaning solution -D 009 401 04-
• Primer applicator -D 009 500 25-
• Adhesive remover -D 002 000 10-
• Cutting cord -357 853 999-

Observe curing period (refer to page 276). Double cartridge gun -VAS 5237- must be used to apply these materials. Small cartridge, 110 ml, for sealing and/or when a 400 ml cartridge alone is not sufficient. Heat according to manufacturer’s instructions, using cartridge heater -V.A.G 1939 A-. Materials are stored in box -D 004 700- .

The installation instructions for the windscreen on the VOLKSWAGEN JETTA 2005 are:

• Prepare used undamaged window for glazing (refer to page 274).
• Prepare new window for glazing (refer to page 274).
• Prepare body flange for glazing (refer to page 275).
• Installation instructions (refer to page 276).
• Minimum curing period (refer to page 276).

The steps for removing the plenum chamber cover for the VOLKSWAGEN JETTA 2005 are:

• Unbolt wiper arms (refer to Electrical system; Repair Group 92; Wiper system).
• Pull plenum chamber seal -4- off over entire length of plenum chamber bulkhead -2-.
• Beginning on right, carefully pull plenum chamber cover -1- upwards out of windscreen seal -5-.

The caution when installing the plenum chamber cover for the VOLKSWAGEN JETTA 2005 is that striking the plenum chamber cover can cause cracks in the windscreen.

The warning when removing the windscreen for the VOLKSWAGEN JETTA 2005 is that an insert is installed in the windscreen seal of new windscreens. Remove this insert before installing the plenum chamber cover.

The warning that applies when cutting through adhesive sealing material while removing the windscreen for the VOLKSWAGEN JETTA 2005 is to always wear safety goggles and leather gloves.

The minimum curing period for 2K adhesive for windows when installing a windscreen for the VOLKSWAGEN JETTA 2005 is three hours.

The minimum curing period for 2K adhesive -DA 004 600 A2- for door outer panel bonding on the VOLKSWAGEN JETTA 2005 is 90 minutes.

The notes regarding cleaning off excess adhesive sealing material for flush bonded windows on the VOLKSWAGEN JETTA 2005 are:

• Use of adhesive remover -D 002 000 10- as a cleaning solution is recommended. Observe the appropriate safety precautions when performing this work.
• When cleaning freshly installed glass from the inside in the vehicle, do not press glass outwards (Warning).
• First clean painted surface as much as possible using a dry cloth. Remove residual excess with adhesive remover -D 002 000 10-.
• Cleaning plastic trim: allow adhesive sealant to cure (approx. one hour) and then peel off.

The specified torque for bolt -3- when removing and installing the door window for the Front door windows on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The caution when removing bolt -3- from the interior when adjusting the door window for the Front door windows on the VOLKSWAGEN JETTA 2005 is to remove bolt -3- from interior by turning it clockwise.

The procedure to test for proper function after installing the door window for the Front door windows on the VOLKSWAGEN JETTA 2005 is to then test for proper function.

The specified torque for bolts -2- when removing and installing the window regulator motor for the Front door windows on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

After running the window regulator twice in each direction to upper and lower stops for the Front door windows on the VOLKSWAGEN JETTA 2005, this initiates and readies the window regulator motor and activates the roll-back function.

The specified torque for bolts -2- when removing and installing the window regulator for the Rear door window (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolts -5- when removing and installing the window regulator for the Rear door window (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolts -2- on the middle frame is 5.5 Nm, and the specified torque for bolts -3- on the middle frame is 4.5 Nm when removing the complete window channel with fixed door window from the window frame for the Rear door window (saloon) on the VOLKSWAGEN JETTA 2005.

The special tool required for pushing trim strip -1- evenly into window channel -2- by hand and then pressing window channel -2- fully into the mounting of trim strip with roller -T 10314- is the roller -T 10314- .

The specified torque for bolts -2- when removing and installing the window regulator motor for the Rear door window (saloon) on the VOLKSWAGEN JETTA 2005 is 3.5 Nm.

The specified torque for bolts -2- when removing and installing the window regulator for the Rear door window (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolts -5- when removing and installing the window regulator for the Rear door window (saloon) on the VOLKSWAGEN JETTA 2005 is 8 Nm.

The special tools and workshop equipment required for the Rear door window (Variant) repair on the VOLKSWAGEN JETTA 2005 are:

• Socket -T10072-
• Assembly tool -T10118-
• Door alignment tool -3320- with -3320/1- , -3320/2- and -3320/3-
• Roller for door insulation foil -3356-
• Torque wrench -V.A.G 1331-
• Setting gauge -3371-

The specified torque for bolts -2- when removing and installing the door window for the Rear door window (Variant) on the VOLKSWAGEN JETTA 2005 is 20 Nm + 1/4 turn further (90°), and bolts -4-, -5- and -11- are also 20 Nm + 1/4 turn further (90°).

The specified torque for bolt -3- when removing and installing the door window for the Rear door window (Variant) on the VOLKSWAGEN JETTA 2005 is 14 Nm.

The special tools and workshop equipment required for the Wheel housing liner repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1783-

The specified torque for bolt -2- in the Assembly overview – front wheel housing liner for the VOLKSWAGEN JETTA 2005 is 2 Nm.

The specified torque for bolt -4- in the Assembly overview – front wheel housing liner for the VOLKSWAGEN JETTA 2005 is 2 Nm.

The special tools and workshop equipment required for the Exterior mirror repair on the VOLKSWAGEN JETTA 2005 are:

• Removal lever -80-200-
• Torque wrench -V.A.G 1783-

The specified torque for bolt -3- in the Assembly overview – exterior mirror for the VOLKSWAGEN JETTA 2005 is 8 Nm.

The specified torque for bolt -4- in the Assembly overview – exterior mirror for the VOLKSWAGEN JETTA 2005 is 1 Nm.

The specified torque for bolt -6- in the Assembly overview – exterior mirror for the VOLKSWAGEN JETTA 2005 is 1 Nm.

The specified torque for bolt -9- in the Assembly overview – exterior mirror for the VOLKSWAGEN JETTA 2005 is 1 Nm.

When removing the mirror glass for the Exterior mirror repair on the VOLKSWAGEN JETTA 2005, always wear safety goggles and leather gloves.

The special tools and workshop equipment required for the Roof railing repair on the VOLKSWAGEN JETTA 2005 are:

• Torque wrench 5…50 Nm -V.A.G 1331-
• Plastic wedge -T10039/1-

The specified torque for bolt -2- in the Assembly overview – roof railing for the VOLKSWAGEN JETTA 2005 is 20 Nm.

The specified torque for bolt -3- when removing the roof railing for the VOLKSWAGEN JETTA 2005 is 20 Nm.

The special tools and workshop equipment required for the Radiator grille repair on the VOLKSWAGEN JETTA 2005 is:

• Torque wrench -V.A.G 1783-

The specified torque for bolt -2- in the Assembly overview – radiator grille for the VOLKSWAGEN JETTA 2005 is 2 Nm.

The special tools and workshop equipment required for the Mouldings and trims repair on the VOLKSWAGEN JETTA 2005 are:

• Torque wrench -V.A.G 1783-
• Double cartridge gun -VAS 5237-
• Hot air blower -V.A.G 1416-
• Removal wedge -3409-

The specified torque for bolts -1- when removing and installing side panel trim strips on GLI vehicles for the VOLKSWAGEN JETTA 2005 is 1.2 ±0.1 Nm.

The specified torque for bolts -1- when installing the side member extension for the Jetta Cup Edition on the VOLKSWAGEN JETTA 2005 is 2 ±0.5 Nm.

The minimum curing period for newly bonded attaching parts for Special add-on parts on the VOLKSWAGEN JETTA 2005 is 3 hours.

The minimum curing period for 2K adhesive -DA 004 600 A2- when replacing bonded windows for the VOLKSWAGEN JETTA 2005 is 180 minutes.

The installation instructions for lettering and emblems on the VOLKSWAGEN JETTA 2005 are:

• Before removal, heat lettering or emblem with a hot air blower -V.A.G 1416-.
• If the lettering or emblem is installed for the first time on a new vehicle and newly painted surfaces, the procedure in Workshop manual “Paint”; Paintwork repairs; Paint finish; Mouldings & Film should be observed.
• If the lettering or emblem is removed and reinstalled, only use adhesive remover -D 002 000 10- to remove the adhesive remains.
• Ensure that bonding surfaces are free of dust and grease.
• Bond lettering or emblem immediately after cleaning.
• Pull protective backing off only directly prior to installation.
• The working temperature is approx. 21 °C.

Dimension -a- is 25 mm from the outer edge of the rear lid to the lettering for Rear lettering dimensions (saloon) on the VOLKSWAGEN JETTA 2005.

Dimension -b- is 15 mm from the lower edge of the tail light aperture in the rear lid to the upper edge of the lettering for Rear lettering dimensions (saloon) on the VOLKSWAGEN JETTA 2005.

Dimension -a- for Lettering (Golf Variant) in Rear lettering dimensions (Variant) on the VOLKSWAGEN JETTA 2005 is 5 mm, which is the lower edge of the lettering to the height of the lower edge of the rear light -1-.

Dimension -a- for Lettering (Jetta Variant) in Rear lettering dimensions (Variant) on the VOLKSWAGEN JETTA 2005 is 25 mm, which involves transferring -dimension a- from the outer edge of the rear lid to the lettering, and the lower edge of the lettering to the height of the upper edge of the rear light -1-.

Dimension -a- for the emblem on the left wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 551 mm, transferred from the lower edge of the wing to the wing.

Dimension -b- for the emblem on the left wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 14 mm, transferred from the end point of dimension -a- to the corner of the emblem.

Dimension -c- for the emblem on the left wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 70 mm, used to check the distance from the upper edge of the emblem to the edge of the wing.

Dimension -d- for the emblem on the left wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 92 mm, used to check the distance from the lower edge of the emblem to the edge of the wing.

Dimension -a- for the emblem on the right wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 550 mm, transferred from the lower edge of the wing to the wing.

Dimension -b- for the emblem on the right wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 30 mm, transferred from the end point of dimension -a- to the corner of the emblem.

Dimension -c- for the emblem on the right wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 86 mm, used to check the distance from the upper edge of the emblem to the edge of the wing.

Dimension -d- for the emblem on the right wing for Side lettering dimensions – Individual on the VOLKSWAGEN JETTA 2005 is 92 mm, used to check the distance from the lower edge of the emblem to the edge of the wing.