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Volkswagen Golf Service & Repair Manual: Corrosion protection for body components, add-on components and welded components

Volkswagen Golf Service & Repair Manual / General information, paint / General notes / Corrosion protection for body components, add-on components and welded components

Attachments
  Wings, doors, covers and flaps must be coated completely on the inside as well. One wet-in-wet spray pass is adequate for this.
  Before installing, add-on parts must be sealed with cavity sealant on the inside in order to restore the original state → Chapter „Anti-corrosion materials“. Please refer to »Vehicle-specific paint information«.
  Vehicles with wheelhousing liners must be provided with additional scuff protection on the wheel arch → Chapter „Corrosion protection measures for wing surface in contact with wheel housing liner“.
Welded parts
  All welded parts, except the roof, must be fully primed and surfaced on the inside. The visible inner surfaces must be coated with one spray pass of base coat and clear coat. This should be done prior to welding-in where necessary. In cases of doubt, the series status applies.
  If sealing is required, perform the respective sealing work after the paintwork structure has been completed.
  Coat all parts that form cavities, such as pillars, braces, side panels, etc., with cavity sealant → Chapter „Anti-corrosion materials“.
All series parts which are coated with noise-damping or anti-chip material (e.g. wheel housing, floor panel, front/rear cross panels or side member) need to be coated as follows:
  Wheel housings and underbody with sprayable seam seal → Chapter „Sealing materials“
  Use adhesive sealant -D 511 500 A2- as foundation material to smooth over larger seams and compensate for deeper layers.
  Coat sill panel area, bottom of side panel and corners of cross panels with anti-chip coating → Chapter „Stone chip guard“.
   
Notes on treating corroded fold areas
Examples for corrosion in the fold area of bonnet, door or rear lid –  Remove corrosion using → Chapter „Pneumatic br ...

Painting parking aid sensor
To avoid malfunctions in the parking aid sensor, always observe the following when painting: Painting new parts   M ...

Other materials:

General information
Repair instructions for repair work on ABS The ABS brake system is divided diagonally. The servo-assistance is effected pneumatically by the vacuum brake servo unit. Vehicles with ABS are not fitted with a mechanical bra ...

Refrigerant circuit seals
Renew seals. Moisten seals with refrigerant oil before installing. Ensure proper seating of seals on the pipe or in the groove. Work in a completely clean environment (the smallest particles ...

Removing and installing brake servo, LHD vehicles
  Note If there are problems with the brake servo, first check the brake servo vacuum system → Chapter. Special tools and workshop equipment required     ...

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