Volkswagen Golf / Golf Plus. Manual - part 125

 

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Volkswagen Golf / Golf Plus. Manual - part 125

 

 

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– Removing remaining material.

Note

When removing the remaining material -1- of the roof, ensure that the side elements -2- (side panels and/

or side panel frames) are not damaged.

Use flap discs only, do not use cutting disks or rough grinding disks.

– Remove all adhesive residue and remaining sealing com‐

pound from the front and rear roof cross members and, in

vehicles without sliding/tilting roof, the roof reinforcement.

– Restore paint structure.

1.3

Installing

Note

The use of different types and different thicknesses of steel re‐

quires that one of the welding units (inverter) listed under Tools

must be used for proper spot welding 

⇒ page 78

 .

Body Repairs - Edition 06.2010

1. Renewing roof    

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1.3.1

Preparing new part

Replacement part
♦ Roof
♦ 1K adhesive -D 190 MKD A3- (3 cartridges)
♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets)
♦ Adhesive sealant -AKD 476 KD5 05-
♦ Felt -533 867 910 B-
♦ Primer -ALN 002 003 04-

Note

The following working sequence must be adhered to in order

to ensure correct and long-lasting roof repairs.

No filler should be applied to the bonding areas before the roof

is bonded in position.

When applying 2K body adhesive, ensure all areas ground

down to bare metal are moistened with adhesive to prevent

subsequent corrosion and blistering.

For this repair, it is absolutely necessary to work with great

care to prevent faults during processing.

– Roughen bonding area on vehicle using fine abrasive paper

(360 grade).

– Sand bonding area -1- on left and right of roof down to bare

metal.

This ensures that 2K body adhesive -D 180 KD3 A2- bonds well

with bonding area.

Body Repairs - Edition 06.2010

82

     Rep. gr.51 - Body - centre

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– As required, place approx. 6-10 felt pads -1- on roof frame on

left and right-hand side.

– Place roof on roof frame and check the position of roof relative

to side panels and side panel frames is correct (visual inspec‐

tion).

Note

Check that the roof is aligned correctly with the rear lid and wind‐

screen.

– Tension two securing belts (commercially available) across

roof.

Body Repairs - Edition 06.2010

1. Renewing roof    

83

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– Align front belt with marking -arrow- in front door openings

used for fitting front roof-top carrier system bars (Figure shows

a vehicle with sliding/tilting roof).

– On both sides of vehicle, measure dimension -a- from marking

-arrow- used for fitting front roof-top carrier system bars to‐

wards rear and then mark this point on vehicle.

Dimension -a- (2-door vehicle) = 685 mm
Dimension -a- (4-door vehicle) = 691 mm
– Tighten rear belt at these markings.

Note

In the case of two-door vehicles with fitted side windows, the rear

belt must be fitted around the whole vehicle.

Body Repairs - Edition 06.2010

84

     Rep. gr.51 - Body - centre

 

 

 

 

 

 

 

Content   ..  123  124  125  126   ..