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A-pillar, replacing -partial section Volkswagen Jetta V

Body Collision Repair -- (A5 Platform) 7 illustrations ~297 words

A-pillar, replacing -partial section

CAUTIONObserve safety precautions in 01 - BODY COLLISION REPAIR - GENERAL INFORMATION . If welding or cutting with spark-producing devices/tools or when plating in foamed areas where gases are produced that are harmful to humans and the environment, these procedures are to be omitted in each case.

Scheme 206

Scheme 206
Scheme 206

Scheme 207

Scheme 207
Scheme 207

1 - Upper separating cut

2 - Molded foam part

Dimension - a - = 195 mm

Note. Foam residue must be removed as much as possible before sanding work.

3 - Separating cut for sill panel

Note. If A-pillar reinforcement must also be replaced, separating cut must be performed 430 mm from front edge of sill panel.

4 - Glued area

Scheme 208

Scheme 208: Removing
Scheme 208: Removing

Note. Only use body repair saw V.A.G 1523 to perform separating cuts.

  1. Perform separating cuts - 1 - according to degree of damage.
  2. Separate original joint.
  3. Remove remaining pieces.

Scheme 209

Scheme 209
Scheme 209
  1. Completely remove adhesive residue and grind sealing surfaces to the bare metal.

Replacement part

  1. A-pillar sub-part with end plate for sill panel
  2. Molded foam part
  3. 2K-body adhesive D 180 KD3 A2
  1. Transfer separating cuts on to new part and cut.

Scheme 210

Scheme 210
Scheme 210
  1. Drill holes for gas-shielded arc plug weld seam, 7 mm.

Observe repair notes

Note. Molded foam part 01 - BODY COLLISION REPAIR - GENERAL INFORMATION .

  1. Apply 2K body adhesive D 180 KD3 A2 in area of adhesive applied during production and in area of door cutout.

Scheme 211

Scheme 211
Scheme 211
  1. Apply sealing cord AKD 497 010 04 R10 in area above upper hinge - 1 -.

Note. New part must be installed within 30 minutes, otherwise bonding properties of adhesive will be impaired.

  1. Fit new part to vehicle standing on its wheels or on alignment bracket set and secure.
  2. Check fit with attaching parts.

Scheme 212

Scheme 212
Scheme 212
  1. Weld separating cuts and connecting area to lower sill panel reinforcement, SG stepped seam.
  1. Reproduce original joint in windshield and door cutouts, straight-line spot weld seam.
  2. Weld seam to A-pillar reinforcement, gas-shielded arc plug weld seam and gas-shielded arc continuous weld seam (staggered).