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Side panel, replacing -partial section Volkswagen Jetta V

Body Collision Repair -- (A5 Platform) 9 illustrations ~491 words

Side panel, 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 358

Scheme 358
Scheme 358

1 - Molded foam part

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

2 - Glued area

Scheme 359

Scheme 359: Removing
Scheme 359: Removing

Note. Only use body repair saw V.A.G 1523 to perform separating cuts. Observe replacement part separating cut at separating cut - 2 -. Perform separating cut - 1 - only on outer plate, do not damage internal reinforcements.

  1. Perform separating cut - 1 - as shown.

Dimension - a - = 200 mm

Dimension - b - = 120 mm

  1. Perform separating cut - 2 - as shown.
  2. Grind outer edge on wheel housing.
  3. Separate original joint.

Scheme 360

Scheme 360
Scheme 360
  1. Grind through laser brazed seam to sealing channel. Do not damage sealing channel lying beneath it.
  1. Separate original joint in rear window cut-out and from luggage compartment - magnified area -.

Scheme 361

Scheme 361
Scheme 361
  1. Separate original joint.
  1. Remove remaining pieces.

Scheme 362

Scheme 362
Scheme 362
  1. Completely remove adhesive residue and grind sealing surfaces to the bare metal.
  2. Clean flanged area on wheelhousing (it must be free of dust and grease).

Replacement part

  1. Side panel sub-part
  2. Molded foam part
  3. 2K-body adhesive D 180 KD3 A2
  4. Adhesive sealant AKD 476 KD5 05

Scheme 363

Scheme 363
Scheme 363
  1. Transfer separating cuts on to new part and cut.
  1. As shown - magnified area - , drill holes on side panel (in area of sealing channel respectively at ends of adhesion area) for gas-shielded arc plug weld seam, 7 mm.

Observe repair notes.

Molded foam part --> 01 - BODY COLLISION REPAIR - GENERAL INFORMATION

  1. Place suitable material behind separating cuts.

Scheme 364

Scheme 364
Scheme 364

Note. Adhesion surfaces must be ground down to bare metal so that adhesive can achieve a long-lasting bond. Do not apply adhesive within distance of 10 mm to welding points - 1 -. For the right side panel, butyl sealing cord must be applied in area of fuel filler neck before welding on. New part must be installed within 30 minutes, otherwise bonding properties of adhesive will be impaired.

  1. Apply 2K body adhesive D 180 KD3 A2 on contact surface facing side panel - shaded area - (1 bead, 3.5 mm).
  2. Apply 2K body adhesive D 180 KD3 A2 (2 beads, 3.5 mm) in adhesion area of wheel housing.
  3. Fit new part to vehicle standing on its wheels or on alignment bracket set and secure.
  4. Check fit with attaching parts.

Scheme 365

Scheme 365
Scheme 365
  1. Weld in side panel, straight-line spot weld seam.
  1. Weld separating cuts, SG stepped seam.

Scheme 366

Scheme 366
Scheme 366
  1. Weld original joint in rear window cut-out, gas-shielded arc plug weld seam and straight-line spot weld seam.
  1. Weld side panel to sealing channel, gas-shielded arc plug weld seam.
  2. Weld in end plate - magnified area - , straight-line spot weld seam.
  3. Flange wheelhousing.
  4. Wipe off escaping adhesive and seal wheel housing.

Note. The optical characteristics of laser brazed seam which no longer exists due to repairs must be reproduced using adhesive sealant AKD 476 KD5 05 .