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