Volkswagen Golf / Golf Plus. Manual - part 163

 

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Volkswagen Golf / Golf Plus. Manual - part 163

 

 

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– Remove remaining material.
– Remove remaining adhesive completely and grind bonded

surface back to bare metal.

– Clean any dust and grease off flange area on wheel arch.

8.3

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 231

 .

8.3.1

Preparing new part

Replacement part
♦ Side panel frame (subpart)
♦ Sealing channel
♦ Moulded foam element
♦ 2K body adhesive -D 180 KD3 A2-
♦ 1K assembly adhesive -D 190 MKD A3-
– Transfer parting cuts to new parts and cut out.
– Drill 7 mm ∅ holes in side panel for SG plug weld seam.

Body Repairs - Edition 06.2010

8. Renewing side panel - partial renewal    

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– Drill 7 mm ∅ holes on sealing channel for SG plug weld seam.

8.3.2

Moulded foam elements

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

General Body Repairs ; General Notes; Moulded foam elements

8.3.3

Welding in

Note

Before starting welding on the right-hand side panel, apply butyl

sealing cord in the area of the fuel filler neck.

– 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

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 prop‐

erties of adhesive will be impaired.

– 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.

Body Repairs - Edition 06.2010

234

     Rep. gr.53 - Body - rear

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

seam.

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

8.3.4

Adapting sealing channel to fit and weld‐

ing in - partial renewal

– Adapting sealing channel to fit and welding in

⇒ „7.3.5 Adapting sealing channel to fit and welding in - partial

renewal“, page 227

 .

Body Repairs - Edition 06.2010

8. Renewing side panel - partial renewal    

235

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RO: 53 61 55 50

9

Renewing inner side panel

(4-door)

WARNING

Observe safety notes!
Welding, parting using spark generating machines/tools or tin‐

ning in foam treated areas creates gases which are hazardous

to health and environment. Therefore, refrain from using these

processes.

⇒ General Information; Body Repairs, General Body Repairs ;

Safety instructions
• Outer side panel already removed

⇒ „8 Renewing side panel - partial renewal“, page 229

 .

• Cross panel member already removed

⇒ „4 Renewing cross panel member“, page 205

• Mounting plate for tail light already removed

⇒ „2 Renewing tail light mounting“, page 197

• Tail light mounting reinforcement already removed

⇒ „3 Renewing reinforcing for tail light mounting plate“,

page 201

Body Repairs - Edition 06.2010

236

     Rep. gr.53 - Body - rear

 

 

 

 

 

 

 

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