Volkswagen Golf / Golf GTI / Jetta. Manual — part 615

51-11

WARNING!

Observe
safety
precautions!

Repair

Manual;
General notes,
Chapter 1,
Safety
precautions

1 - Glued

area

51 03 55 20 Roof, replacing (Jetta wagon)

13/2/2005

51-12

Separating

locations

Note:

- Drill out

original
bond to
roof frame

- Grind

through
rear
soldering
points.

Brazing

solder at
vehicle
must be
completely
ground off.

- Roughly cut

out roof in
area
between C-
and D-
pillar.

- Remove

roof.

51 03 55 20 Roof, replacing (Jetta wagon)

13/2/2005

51-13

Note:

- Remove

sealing
compound
from
sealing
channel.

- Grind

surface of
laser weld
seam and
use chisel
to bend up
remaining
pieces and
lever off.

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
surface
down to
bare metal.

51 03 55 20 Roof, replacing (Jetta wagon)

13/2/2005

51-14

Replacement parts

Preparing new part

- Grind spot flanges down to bare

metal from inside using a wire
brush.

Roof

Butyl adhesive sealing cord AKL

450 005 05

Adhesive: DA 001 730 A1

- 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).

- If necessary, drill holes for roof

rail

Page 51-17

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51 03 55 20 Roof, replacing (Jetta wagon)

13/2/2005