Volkswagen Golf / Golf GTI / Jetta. Manual — part 641

53-54

Foamed area

Repair notes

Page 00-6

CAUTION!

New part must be welded with in
30 min., otherwise adhesion
properties are affected.

Welding in place

- Apply 2 - 3.5 mm dia. (0.14 in.)

beads adhesive to flange.

- Place support material behind

weld joints.

- Install and secure new part with

vehicle on wheels or fixture.

- Check gaps/mating lines

dimensions with adjacent parts.

- Butt weld cut, SG-weld seam

continuous.

- Weld remainder, SG-plug weld

seam.

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

13/2/2005

53-55

- Weld quarter panel, RP-spot

weld.

- Reform/compress wheel house

flange.

- Wipe off excess adhesive and

seal.

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

13/2/2005

53-56

53 55 55 00
Quarter panel,
partial
replacement
(Jetta)

Cutting location

1 - Reinforcement

Sits directly

behind high
lighted area.

2

-

Dampener/insulation

Combined

reinforcement
1- and quarter
panel, partial
replacement
cutting line

3 - Foamed area

4 - Bonded area

53 55 55 00 Quarter panel, partial replacement (Jetta)

13/2/2005

53-57

Notes:

CAUTION!

Study

replacement
part blank

Separation

cuts made
only with
body saw
VAG1523 or
with air
hammer
VAG1577.

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.

- Place lower

separating
cut above
rocker panel.

- Grind wheel

house outer
edge.

- Roughly cut

out quarter
panel.

- Remove

excess
material.

53 55 55 00 Quarter panel, partial replacement (Jetta)

13/2/2005