Volkswagen Golf / Golf GTI / Jetta. Manual — part 640

53-46

Replacement part

Long member

Rear long member

Adhesive butyl ADL 450 005 05

Dampener/insulation

Preparing new part

- Transfer separating lines to new part and cut

out.

Welding in place

- Position long member relative to adjoining parts

and secure.

- Butt weld long member, SG-plug weld seam.

- Spot weld rear long member, RP-spot weld.

- Apply butyl adhesive to dampener/insulation and

press onto long member.

- Spot weld rear long member,

Page 53

53 47 55 52 Long member, partial replacement (Jetta)

13/2/2005

53-51

53 55 55 10
Quarter
panel,
partial
replacement
(Golf 4-
door)

WARNING!

Note:

Make separation
cuts only with body
saw VAG1523 or
with air hammer
VAG1577.

1 - Foamed

area

2 - Bonded

area

Welding,
separating
using spark
generating
tools in the
foam area
creates gases,
therefore, do
not use these
processes.

Use 2-K filler
material to
smooth out
irregularities.

- Before

performing
grinding work
scrape out as
much foam
residue as
possible.

53 55 55 10 Quarter panel, partial replacement (Golf 4-door)

13/2/2005

53-52

Cutting

location

Note:

Record
replacement
part cut.

- Make cut to

C-pillar
according
to degree
of damage.

- Make lower

cut above
rocker
panel.

- Roughly cut

out quarter
panel.

- Grind outer

edge of
wheel
house.

- Separate

original
joint.

53 55 55 10 Quarter panel, partial replacement (Golf 4-door)

13/2/2005

53-53

Replacement part

Preparing new part

- Remove residue

- Completely remove adhesive

residue and grind surface smooth.

Partial quarter panel

Adhesive DA 001 730 A1

Dampener/insulation

- Transfer separation lines to new

part and cut out high lighted area.

- Drill holes in flange area of new

part.

- Clean/degrease flange.

53 55 55 10 Quarter panel, partial replacement (Golf 4-door)

13/2/2005