Volkswagen Golf Service & Repair Manual: Notes on treating corroded fold areas
| Examples for corrosion in the fold area of bonnet, door or
rear lid |
| – |
Remove corrosion using
→ Chapter „Pneumatic brush grinder set -VAS 6446-“ or
→ Chapter „Brush grinder set -VAS 6776-“. |
| – |
Smooth off transitions using sandpaper (P360 to P400 grade). |
| – |
Clean substrate using silicon remover. |
| – |
After a corrosion damage has been repaired and before
sealing, isolate substrate using 2-pack wash primer -LHV 043 000
A2-, and then apply 2-pack HS Performance surfacer. |
| – |
As soon as the surfacer is completely dry, treated areas
must be dry-sanded using P400 to P500 sandpaper. When sanding,
take particular care not to “sand through”. Afterwards, clean
sanded surfaces with silicon remover. |
| – |
After sanding the dry surfacer, the metal edges in the fold
area must be sealed with fine seam sealant
→ Chapter „Sealing materials“. Ensure that the fine
seam seals are identical in appearance to the original seam
seals, as specified in the
→ »Vehicle-specific paintwork information« for the
particular vehicle. |
 Note
| |
Seam seals made during repair work must be identical in
appearance and thickness to the original seam seals. |
| |
To avoid damage or faulty operation, brush seam seals smooth
near attachments which must be attached. |
| |
Water drainage holes must remain clear. |
| |
All threaded studs and welded nuts with metric threads as
well as all other studs and contact surfaces for assembly must
be functional following the extent of the sealing work. |
| |
Sealant must never be applied to bare metal. Substrates must
always be coated with surfacer first. |
| – |
Restore paintwork structure according to the paintwork
repair manual. |
| – |
Apply cavity sealant along entire fold area using
→ Chapter „Suction feed spray-gun -V.A.G 1538-“;
→ Chapter „Anti-corrosion materials“. |
Note
| The repair can only be considered successful if the fold
area is sealed air-tight from inside (so that no ingress of
moisture is possible). |
|
|
|
| |
|
Cavity sealing, rear lid |
| |
|
Cavity sealing, bonnet |
| |
|
Cavity sealing, door |
Note
The corrosion protection measure is to be carried out in the groove
of the wing of all new replacement parts which have not had the
additional sealant applied ...
Attachments
Wings, doors, covers and flaps must be coated completely on
the inside as well. One wet-in-wet spray pass is adequate for
...
Other materials:
Removing and installing control unit and hydraulic unit, LHD vehicles,
four-wheel drive, »R«
Special tools and workshop equipment required
Torque wrench -V.A.G 1331-
Torque wrench -V.A.G 1410-
Brake pedal depressor -V.A.G 1869/2-
Sealing plugs, assemb ...
Indicator lamps
First read and observe the introductory information
and safety warnings
Lit up
Possible cause
Solution
The vehicle is being held by the electronic parking
brake.
Switch off the Auto Hold function if necessary .
...
Checking pistons and cylinder bores
Checking piston
–
Using a micrometre, measure approx. 10 mm from the lower
edge, perpendicular to the piston pin axis.
Maximum deviation from nominal dimension: 0.04 mm
...
© 2016-2026 Copyright www.vwgolf.org
Corrosion protection measures for wing surface in contact with wheel housing
liner
Corrosion protection for body components, add-on components and welded
components