Volkswagen Golf / Golf GTI / Jetta. Manual — part 642

53-58

- Remove adhesive residue completely and grind

flange smooth and clean

Replacement part

Partial quarter panel

Adhesive DA 001 730 A1

Dampener/insulation

Adhesive butyl AKL 450 005 05

AKD 476 KD5 05

Preparing new part

- Transfer separating lines to new part and cut out

high lighted area.

- Drill new part in flange/contact area.

- Clean/degrease flange area.

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

13/2/2005

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Foamed area

- Bond dampener/insulation -1-

both sides with butyl bead and
press securely to C-pillar
reinforcement.

- Apply AKD 476 KD5 05 on lower

edge for striker reinforcement (on
quarter panel).

Note:

Study repair notes

Page 00-6

.

CAUTION!

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

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

beads of adhesive on flange -2-.

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

13/2/2005

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Welding in place

- Install and secure new part with vehicle on

wheels or fixture.

- Check gaps/mating lines dimensions with

adjacent parts.

Note:

Before welding right quarter panel, apply bead of
butyl -1- at fuel filler neck area.

- Butt weld seam, SG-weld continuous seam

- Weld remaining seam, SG-plug weld seam.

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

13/2/2005

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- Reform/compress wheel house

flange.

- Wipe off excess adhesive and

seal.

Note:

Fuel filler neck area must be sealed
additionally with AKD 476 KD5 05

- Weld quarter panel, RP-spot

weld, SG-plug weld.

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

13/2/2005