Volkswagen Golf / Golf Plus. Manual - part 161

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– On the side panel mark the area in which, for safety reasons

»crash safety«, no welding work may be carried out.

Dimension -a- = 45 mm
Dimension -b- = 145 mm

Note

The measurements given must be adhered to.

7.3.3

Moulded foam elements

Follow repair instructions.
Moulded foam element ⇒ General Information; Body Repairs,

General Body Repairs ; General Notes; Moulded foam elements

7.3.4

Welding in

– Place backing material behind parting cuts.

– Apply 1K assembly adhesive -D 190 MKD A3- (12 mm high

triangular shaped bead) in bonding area -1- and apply 2K body

Body Repairs - Edition 06.2010

7. Renewing side panel - partial renewal    

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adhesive -D 180 KD3 A2- in bonding area -2- (2 x 3.5 mm ∅

beads).

Note

♦

New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.

♦

Before starting welding on the right-hand side panel, apply butyl sealing cord in the area of the fuel filler

neck.

– Adapt new part with vehicle standing on its wheels or on align‐

ment bracket set and fix in position.

– Check fit with bolt-on parts.

Note

Note that no welding work may be carried out in area -1-.

– Weld in side panel, RP spot weld seam and SG plug weld

seam.

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     Rep. gr.53 - Body - rear

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– Weld transition to side member reinforcement, staggered SG

continuous weld seam.

– Weld in parting cuts, SG stepped weld seam.
– Reform wheel housing flange.
– Wipe away excess adhesive and seal wheel arch.

7.3.5

Adapting sealing channel to fit and weld‐

ing in - partial renewal

– Adapt sealing channel to fit and hold in position.

– Weld in sealing channel, SG plug weld and SG stepped weld

seam.

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7. Renewing side panel - partial renewal    

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– Reinstate original joint, RP spot weld seam.

Note

The optic of the original soldered seam must be recreated using

adhesive sealing compound -AKD 476 KD5 05- .

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     Rep. gr.53 - Body - rear