Volkswagen Golf / Golf GTI / Jetta. Manual — part 649

53-86

Note:

- Make additional holes for SG-plug

weld 7 mm dia. (0.27 in.)

SG-spot weld should be placed

15mm (0.59 in.) apart to maintain
factory produced integrity.

SG-spot welds should be made

from the outside for optical
reasons.

CAUTION!

New part must be welded with in
30 min., otherwise adhesion
properties are affected.

- Bond deadener -1- with Butyl

bead all around and press in long
member.

- Apply adhesive -2-.

53 80 55 50 Spare wheel well, replacing (Jetta)

13/2/2005

53-87

Welding in

place

Note:

Begin SG-spot
welding -1-, -2-
, and -3- from
the outside

- Install and

secure new
part with
vehicle on
wheels or
fixture.

- Check

gaps/mating
lines.

- Weld

quarter
panel, RP-
spot weld
seam.

53 80 55 50 Spare wheel well, replacing (Jetta)

13/2/2005

Select a topic

50 - Body, front

Body, front

Tools

Lock carrier with attachments, removing and installing

Lock carrier service position

Front fender, assembly overview

Fender gaps

Noise insulation (gasoline engines), assembly overview

Noise insulation (Diesel engines), assembly overview

55 - Hood, lids

Hood

Assembly overview

Hood, adjusting

Gas-filled strut, removing

Bowden cable, removing and installing

Release lever, removing and installing

Hood lock, assembly overview

Hood lock, removing and installing

Rear lid (Golf)

Tools

Rear lid (Golf), assembly overview

Gas-filled strut, removing

Releasing gas from gas-filled strut

Rear lid, adjusting

Rear lid lock, removing and installing

Lock cylinder housing, removing and installing

Rear lid (Jetta)

Tools

Rear lid (Jetta), assembly overview

Rear lid lock, removing and installing (Jetta)

Lock cylinder housing, removing and installing

Micro-switch, removing and installing

Rear lid, (Jetta Wagon)

Rear lid (Jetta Wagon), assembly overview

Rear lid lock, removing and installing

Lock cylinder housing, removing and installing

Micro-switch, removing and installing

Tank flap unit

Fuel flap unit, removing and installing (Golf)

Fuel flap unit, removing and installing (Jetta)

57 - Front doors, Central locking system

Front door

Tools

Body Exterior

13/2/2005

Front door, assembly overview

Door, removing and installing

Door, adjusting

Door handle and lock, assembly overview

Lock cylinder housing, removing and installing

Door handle, removing and installing

Door lock, removing and installing

Locking knob for locking rod, removing and installing

Door seals

Auxiliary seal, removing and installing

Central locking system

Comfort system and central locking system, assembly overview

Batteries for key with radio remote control (not foldable), removing
and installing 04.01

Batteries for key with radio remote control (foldable), removing and
installing 04.01

Batteries for key with radio remote control (foldable) removing and
installing 05.01

Adaptation of keys with radio remote control

58 - Rear doors

Rear doors

Tools

Rear door, assembly overview

Door, removing and installing

Door, adjusting

Door handle and door lock, assembly overview

Door handle, removing and installing

Door lock, removing and installing

Door window, assembling to window regulator

Door seals

60 - Sunroof

Sunroof

Tools

General Information

Function

Distinguishing features of Webasto and Rockwell (Meritor) sunroofs

Sunroof with glass panel (Webasto)

Sunroof with glass panel, assembly overview

Removing glass panel for sunroof

Glass panel for sunroof, installing

Glass panel for sunroof (height adjustment), adjusting

Panel seal, replacing

Wind deflector, removing

Sliding headliner, removing

Drive motor for sunroof, removing

Drive motor for sunroof, adjusting (zero position)

Automatic rotary switch for sunroof, removing

Parallel movement, checking

Body Exterior

13/2/2005