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Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
rights reserved.
00 –Technical data
1Basic instructions
(VKI000481; Edition 04.2020)
Only selected labour operations are described in this workshop manual. For labour operations that are not described, remove original part and install replacement part to restore original con‐dition. Repairs that deviate from standard repair methods are described.
If part sections are supplied, adapt these to fit (unless otherwise instructed), butt these up and weld in with SG continuous weld seam.
Observesafetynotes⇒GeneralInformation;BodyRepairs,Gen‐eral Body Repairs ; Safety notes
Makesuretouseanextractionsystemwhencarryingoutwelding and grinding work.
Clean the extraction system at regular intervals.
Never carry out welding and grinding processes in same room at same time.
Remove dust regularly from work areas.
Do not blow off dust deposits with compressed air.
Make sure to observe the respective country-specific accident prevention and health and safety regulations. Jetta 2011 ➤ , Jetta 2013 ➤ Body Repairs - Edition 04.2020
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Body Repairs - Edition 04.2020
4Body work for which HV electrical system must be de-energised
4.1 ThefollowingbodyworkrequirestheHV electrical system to be de-energised.
Always de-energise the high-voltage system via Guided Fault Finding, De-energising high-voltage system.
A high-voltage technician must de-energise the system prior to welding, grinding and cutting work in the vicinity of high-voltage components.
A high-voltage technician must de-energise the system prior to body work with the alignment jig.
De-energisation measures may only be carried out by electrically instructed persons.
Jetta 2011 ➤ , Jetta 2013 ➤
5Moulded foam inserts
Various cavities in the bodywork of this vehicle are fitted with moulded foam inserts.
Themouldedfoaminsertsreducetheamountofdrivingnoisethat is transmitted into the interior.
The exact location of these moulded foam inserts are shown at the beginning of the respective repair description.
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The exact location of these moulded foam inserts are shown at the beginning of the respective repair description.
–Apply corrosion protection measures according to guidelines in ⇒ Paint workshop manual: Corrosion and corrosion pro‐tection, attached and welded parts, materials .
le,
Prerequisites
Before continuing with this procedure, ensure that the part for re‐placementhasbeenpreparedforinstallation,e.g.cut,adaptedto fit; received corrosion protection measures.
h - 3.5 mm ± 0.5 mm Jetta 2011 ➤ , Jetta 2013 ➤ Body Repairs - Edition 04.2020
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8.6Floor panel - rear
a - 1075 mm ± 2.0 mm
Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
a - 987 mm ± 2.0 mm
b - 1261 mm ± 2.0 mm
c - 1000 mm ± 2.0 mm
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9Contour correct surfaces
A contour correct surface is a surface of accurate dimensions in regard to edges and sculpture lines.
This is achieved when:
♦ The body repair specialist has worked repair surfaces and parts, such as after repairing dents, welding and filler, using material of a graining of P 80.
♦ The vehicle painter can restore the surface in maximum two stages.
For a contour correct surface, steel filler from 2-pack steel filler set - DA 787 300 A2may be used.
11.2Procedure for body structural damage on vehicles from Volkswagen
• If body structural damage or deviation from dimensions given in the repair manual is suspected and/or damage is visible to structuralcomponents,thevehiclemustbeplacedonaVolks‐wagen AG approved alignment jig system and measured.
Explanation of structural damage to body:
A damaged (dented, cracked, buckled) component and/or the position of the structural component on the body has changed.
A structural component includes all components of the body, ex‐cept outer body panels and components which are bolted on. If dimensions deviate, the vehicle must be repaired according to respective repair manual.
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Jetta
–Separate original joint.
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–Adapt new part with vehicle positioned on alignment bracket set and fix in place.
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– Separate original joint between upper outer longitudinal mem‐ber and upper inner longitudinal member as well as to A-pillar.
– Cutoutbulkheadpart-2-togetherwithupperinnerlongitudinal member -1-.
Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
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–Separate original joint and bonded areas -2- on upper inner longitudinal member -1-.
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–Remove remaining adhesive completely, and sand bonding surfaces down to bare metal.
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–Build up corrosion protection as per guidelines in ⇒ Paint workshop manual; Corrosion; Corrosion protection; Attached and welded parts; Materials on bonding surfaces where no welding is to take place.
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Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
– Apply 2-component body adhesive - D 180 KD3 A2- to area of factory-applied bonded joint on wheel housing.
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♦ Longitudinal member reinforcement (parts designation: bulk‐head plate)
♦ Front bumper bracket Jetta 2011 ➤ , Jetta 2013 ➤ Body Repairs - Edition 04.2020
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–Transfer parting cut to longitudinal member and longitudinal member cover plate and cut out.
9.3.2Welding in
– Adaptnewpartwithvehiclestandingonitswheelsoronalign‐ment bracket set and hold in position.
–Check fit with adjacent parts.
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–Weld in longitudinal member parting cut (all round), SG con‐tinuous weld seam.
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Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
–Weld in longitudinal member reinforcement, RP spot weld seam.
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–Weld in longitudinal member reinforcement, RP spot weld seam.
–Weld parting cut, SG continuous weld seam.
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–Weld in cover plate, RP spot weld seam.
–Weld parting cut of cover plate, SG continuous weld seam.
–Shorten new longitudinal member with cover plate and weld in bumper holder ⇒ page 96
Jetta
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Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
51 –Body - centre
RO: 51 03 55 00
1 Renewing roof - vehicles with no slid‐ing/tilting sunroof
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Jetta
–Remove remaining material -2-.
–Remove remaining adhesive completely, and sand bonding surfaces down to bare metal.
–Build up corrosion protection as per guidelines in ⇒ Paint workshop manual; Corrosion; Corrosion protection; Attached and welded parts; Materials on bonding surfaces where no welding is to take place.
♦ 2-component body adhesive - D 180 KD3 A2- (2 cartridge sets)
♦ Adhesive sealant - AKD 476 KD5 05-
♦ Felt - 533 867 910 B-
♦ Cavity sealant - AKR 321 M15 4-
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–Lightly sand down bonding areas -1- on left and right of roof. This ensures that the 2-component body adhesive - D 180 KD3 A2- bonds well with bonding surfaces.
–Attach four suction lifters - V.A.G 1344- to the exterior of the roof.
–Cut approx. 2 mm off nozzle -B- to provide appropriate bead geometry.
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–Then apply 1K assembly adhesive - D190 MKD A3- to front and rear roof cross members in area of factory-fitted bond us‐ing pneumatic cartridge gun - V.A.G 1761/1- .
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–Apply 1K assembly adhesive - D190 MKD A3- to roof rein‐forcement in area of the factory-fitted bonds using com‐pressed air gun - V.A.G 1761/1- .
All vehicles:
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In the area of the roof frame, apply 1K assembly adhesive - D190 MKD A3- -1- with the pneumatic cartridge gun - V.A.G 1761/1- .
Dimension -a- = approx. 10 mm
Dimension -b- = approx. 11 mm
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AG. Volks
Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
– Apply1Kassemblyadhesive-D190MKDA3--1-oninnerside of roof parallel to left and right roof flange with pneumatic car‐tridge gun - V.A.G 1761/1- .
–Cut first step of static mixer -A- off to achieve corresponding bead cross-section.
–Carefully operate double cartridge gun - VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector.
–Screw static mixer onto cartridge connector.
– Applythefirst100mmofadhesivetoapieceofcardboardand only then begin to apply the adhesive to the vehicle.
– Fillarea-1-with2-componentbodyadhesive-D180KD3A2using double cartridge gun - VAS 5237- .
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Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
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–Coat roof flanges with 2-component body adhesive - D 180 KD3 A2- -1-.
–Immediately position and align roof.
– Secure roof at front and rear window apertures using vice-grip pliers and also secure centre of roof using tensioning straps.
–Check roof depth dimension -a- and adjust if necessary ⇒ page 114
– Remove excessive 2-component body adhesive - D 180 KD3 A2- along edge of roof immediately using a cloth soaked in silicone remover - LSE 020 100 A3- .
1.3.4Welding in –Weld roof in front and rear window apertures, RP spot weld seam.
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Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
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– Apply adhesive sealant - AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. –After painting, preserve roof cavities -arrow- with corrosionpreventive wax - AKR 321 M15 4- .
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–Remove remaining material -2-.
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–Remove remaining adhesive completely, and sand bonding surfaces down to bare metal.
–Build up corrosion protection as per guidelines in ⇒ Paint workshop manual; Corrosion; Corrosion protection; Attached and welded parts; Materials on bonding surfaces where no welding is to take place.
–Cut approx. 2 mm off nozzle -B- to provide appropriate bead geometry. Jetta 2011 ➤ , Jetta 2013 ➤ Body Repairs - Edition 04.2020
Volkswagen
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Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
isnotpermittedunlessauth –Then apply 1K assembly adhesive - D190 MKD A3- to front and rear roof cross members in area of factory-fitted bond us‐ing pneumatic cartridge gun - V.A.G 1761/1- .
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In the area of the roof frame, apply 1K assembly adhesive - D190 MKD A3- -1- with the pneumatic cartridge gun - V.A.G 1761/1- .
Dimension -a- = approx. 10 mm
Dimension -b- = approx. 11 mm
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e ss o f ni
Jetta 2011 ➤ , Jetta 2013 ➤
Body Repairs - Edition 04.2020
– Apply1Kassemblyadhesive-D190MKDA3--1-oninnerside of roof parallel to left and right roof flange with pneumatic car‐tridge gun - V.A.G 1761/1- .
–Cut first step of static mixer -A- off to achieve corresponding bead cross-section.
–Carefully operate double cartridge gun - VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector.
–Screw static mixer onto cartridge connector.
– Applythefirst100mmofadhesivetoapieceofcardboardand only then begin to apply the adhesive to the vehicle. – Fillarea-1-with2-componentbodyadhesive-D180KD3A2using double cartridge gun - VAS 5237- . Jetta 2011 ➤ , Jetta 2013 ➤ Body Repairs - Edition 04.2020
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–Coat roof flanges with 2-component body adhesive - D 180 KD3 A2- -1-.
–Immediately position and align roof.
– Secure roof at front and rear window apertures using vice-grip pliers and also secure centre of roof using tensioning straps.
–Check roof depth dimension -a- and adjust if necessary ⇒ page 130
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– Remove excessive 2-component body adhesive - D 180 KD3 A2- along edge of roof immediately using a cloth soaked in silicone remover - LSE 020 100 A3- .
– Weld reinforcing frame to inside of side panel, SG continuous weld seam.
– Apply adhesive sealant - AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. –After painting, preserve roof cavities -arrow- with corrosionpreventive wax - AKR 321 M15 4- .
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–Separate original joint to console on left and right.
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